Documente Academic
Documente Profesional
Documente Cultură
S K Mondals
1.
Chapter 1
Design of Joint
Theory at a glance (IES, IAS, GATE & PSU)
Cotters
In machinery, the general term shaft refers to a member, usually of circular crosssection, which supports gears, sprockets, wheels, rotors, etc., and which is subjected to
torsion and to transverse or axial loads acting singly or in combination.
An axle is a non-rotating member that supports wheels, pulleys, and carries no
torque.
A spindle is a short shaft. Terms such as line-shaft, head-shaft, stub shaft,
transmission shaft, countershaft, and flexible shaft are names associated with special
usage.
A cotter is a flat wedge-shaped piece of steel as shown in figure below. This is used to connect
rigidly two rods which transmit motion in the axial direction, without rotation. These joints
may be subjected to tensile or compressive forces along the axes of the rods.
Examples of cotter joint connections are: connection of piston rod to the crosshead of a steam
engine, valve rod and its stem etc.
A typical cotter joint is as shown in figure below. One of the rods has a socket end into which
the other rod is inserted and the cotter is driven into a slot, made in both the socket and the
rod. The cotter tapers in width (usually 1:24) on one side only and when this is driven in, the
rod is forced into the socket. However, if the taper is provided on both the edges it must be less
than the sum of the friction angles for both the edges to make it self locking i.e. 1 + 2 < 1 + 2
where 1 , 2 are the angles of taper on the rod edge and socket edge of the cotter respectively
and 1 , 2 are the corresponding angles of friction. This also means that if taper is given on
Page 1 of 263
Design of Joint
S K Mondals
Chapter 1
one side only then < 1 + 2 for self locking. Clearances between the cotter and slots in the
rod end and socket allows the driven cotter to draw together the two parts of the joint until the
socket end comes in contact with the cotter on the rod end.
d3
d1 d2
d 2 t = P
Page 2 of 263
Design of Joint
S K Mondals
Chapter 1
4 d1 d1t t = P
2
2
4 d2 d1 ( d2 d1 ) t t = P
2bt = P
2l1d1 = P
2l ( d3 d1 ) = P
Page 3 of 263
Design of Joint
S K Mondals
Chapter 1
d1t c = P
( d3 d1 ) t c
=P
(d
4
d12 c = P
d1t1 = P
Page 4 of 263
Design of Joint
S K Mondals
Chapter 1
P d3 d1 d1
+ and
2 6
4
P d3 d1 d1 b
d d1 d1
3P 3
+
+
2 6
4 2
6
4
=
( b ) =
3
2
tb
tb
12
Tightening of cotter introduces initial stresses which are again difficult to estimate.
Sometimes therefore it is necessary to use empirical proportions to design the joint. Some
typical proportions are given below:
d1 = 1.21.d
d4
1.5.d
= l = l1 = 0.75d
d2 = 1.75.d
t = 0.31d
t1 = 0.45d
d3 = 2.4 d
b = 1.6d
c = clearance
A design based on empirical relation may be checked using the formulae based on failure
Mechanisms.
Question: Design a typical cotter joint to transmit a load of 50 kN in tension or compression.
Consider that the rod, socket and cotter are all made of a material with the following
allowable stresses:
Allowable tensile stress ( y )= 150 MPa
Allowable crushing stress (c) = 110 MPa
Allowable shear stress (y) = 110 MPa.
Answer: Refer to figures
Page 5 of 263
Design of Joint
S K Mondals
Chapter 1
d3
Axial load
(P ) =
d1 d2
2 mm in increment
5 mm in increment
10 mm in increment
15 mm in increment
20 mm in increment
30 mm in increment
d1t = 1.58x10-4m2. From empirical relations we may take t=0.4d i.e. 10 mm and this
gives d1= 15.8 mm. Maintaining the proportion let d1= 1.2 d = 30 mm.
Refer to figure
d2 d12 ( d2 d1 ) t y = P
Page 6 of 263
Design of Joint
S K Mondals
Chapter 1
Refer to figure
For crushing failure of socket or rod (d3-d1)tc = P. This gives d3 = 75.5 mm. Let d3 = 77
mm.
Refer to figure
For crushing failure of collar
(d
4
2
4
Knuckle Joint
A knuckle joint (as shown in figure below) is used to connect two rods under tensile load. This
joint permits angular misalignment of the rods and may take compressive load if it is guided.
d3
d2
t1
t
t1
t2
d
t2
d1
Figure- A typical knuckle joint
These joints are used for different types of connections e.g. tie rods, tension links in bridge
structure. In this, one of the rods has an eye at the rod end and the other one is forked with
eyes at both the legs. A pin (knuckle pin) is inserted through the rod-end eye and fork-end eyes
and is secured by a collar and a split pin.
Normally, empirical relations are available to find different dimensions of the joint and they
are safe from design point of view. The proportions are given in the figure above.
d1 = d
d = diameter of rod
t = 1.25d
d2 = 2d
d3 = 1.5.d
t1 = 0.75d
t2 = 0.5d
Page 7 of 263
Design of Joint
S K Mondals
Chapter 1
However, failures analysis may be carried out for checking. The analyses are shown below
assuming the same materials for the rods and pins and the yield stresses in tension,
compression and shear are given by t, c and .
1. Failure of rod in tension:
d 2 t = P
d12 = P
3. Failure of knuckle pin in bending (if the pin is loose in the fork)
Assuming a triangular pressure distribution on the pin, the loading on the pin is shown in
figure below.
Equating the maximum bending stress to tensile or compressive yield stress we have
t
t
16P 1 +
3 4
t =
d13
Page 8 of 263
Design of Joint
S K Mondals
Chapter 1
2P
d12
Two mild steel rods are connected by a knuckle joint to transmit an axial
force of 100 kN. Design the joint completely assuming the working stresses for
both the pin and rod materials to be 100 MPa in tension, 65 MPa in shear and
150 MPa in crushing.
d3
d2
t1
t
t1
t2
d
t2
d1
Refer to figure above
For failure of rod in tension, P
have d= 35.6 mm. Let us choose the rod diameter d = 40 mm which is the next standard size.
We may now use the empirical relations to find the necessary dimensions and then
check the failure criteria.
d1= 40 mm
d2 = 80 mm
d3 = 60 mm
t= 50 mm
t1= 30 mm;
t2= 20 mm;
Page 9 of 263
Design of Joint
S K Mondals
Chapter 1
P 2 d12 = y
4
2.
t
t
16P 1 +
3 4 . On substitution
For failure of knuckle pin in bending: y =
d13
this gives y = 179 MPa which is more than the allowable tensile yield stress of 100
MPa. We therefore increase the knuckle pin diameter to 55 mm which gives y = 69
MPa that is well within the tensile yield stress.
t = 50 mm
t1= 30 mm; and d = 40 mm
t2= 20 mm;
Keys
In the assembly of pulley, key and shaft, Key is made the Weakest so that it is cheap and easy
to replace in case of failure.
Page 10 of 263
Des
sign of
o Join
nt
S K Monda
M
als
Chapte
er 1
Rectan
ngular and sq
quare ke
ey
1. Rectangular sunk key:: A rectangu
ular sunk key
k is shown
n in figure below. The usual
pro
oportions of this key aree:
Width of key, (w))
Thickn
ness of key
y, (t)
=d/4
= 2w / 3 = d / 6
here d = Dia
ameter of th
he shaft or d
diameter of the
t hole in the
t hub.
Wh
Thee key has ta
aper 1 in 100 on the toop side only.
Page 11 of 263
Desig
gn of Joint
S K Mo
ondals
C
Chapter
r1
Figu
ure-. Rectan
ngular sunk
k key.
2.. Square su
unk key: The
T only diffference betw
ween a rectangular sun
nk key and a square su
unk
ke
ey is that its width and
d thickness are
a equal, i..e.
w=t=d/4
ar sunk key
y with a hea
ad at one en
nd known as
a gib head
d. It
3.. Gib-head key: It is a rectangula
is usually prrovided to fa
acilitate thee removal oof key. A gib
b head key is shown in figure below
an
nd its use in
n shown in figure
f
below
w.
Width,
W
(w
w)
Thicknes
T
ss at larg
ge end, ( t )
=d/4
=2w
w/3=d/6
or
o x =
Q.
Q
8T
d2
ld
d d
4 l x 2 = T
So
olution: Co
onsider a re
ectangular key of widtth (w), thick
kness (t) an
nd length (L
L) as shown
n in
figure below.
b
The key
k may faill (a) in shear or (b) in crrushing.
Page 12 of 263
Des
sign of
o Join
nt
S K Monda
M
als
Chapte
er 1
Figure
Shear failure
e: The failu
ure criterio
on is
Wh
here torque
e transmittted is,
= y w L
d
2
2 N
60
(T ) = Poweer /
N being
b
in rpm
m, w, L and d are the w
width, length
h and diameter of the shaft
s
respecctively
and
d y is the yield
y
stress in
i shear of tthe key matterial. Takin
ng y to be half
h
of the tensile
t
yield stress an
nd substituting the valu
ues in above
e equations and we hav
ve wL = 2.19
9 x 104 m2.
ushing faillure
Cru
= c
t L d
2 2
Flat ke
ey
A flat key
y, as shown
n in figure below
b
is use
ed for light load beca
ause they deepend entirrely on
friction forr the grip. The
T
sides of
o these key
ys are paralllel but the top is sligh
htly tapered
d for a
tight fit. Theses
T
keys have aboutt half the thickness of sunk keys.
Saddlee key
Flat key
Saddle
e key
A saddle key, shown
n in figure above,
a
is very similar to
t a flat key
y except tha
at the bottom
m side
is concavee to fit the shaft
s
surfacce. These keeys also hav
ve friction g
grip and therefore cann
not be
used for heavy
h
loads. A simple pin
p can be u
used as a ke
ey to transm
mit large to
orques. Very
y little
stress conccentration occurs
o
in the
e shaft in th
hese cases. This
T
is show
wn in figuree above.
Tange
ent Key
Page 13 of 263
Desig
gn of Joint
S K Mo
ondals
C
Chapter
r1
Figure- Tangent
T
Key
Feather
F
key
A feather key
y is used wh
hen one com
mponent slid
des over anoother. The k
key may be fastened
f
either
too the hub or the shaft and
a the keyw
way usually
y has a slidin
ng fit.
Figure- feather
f
key
Woodru
W
uff key
A woodrufff key is a form
fo
of sunk
k key wherre the key shape
s
is tha
at of a trun
ncated disc,, as
sh
hown in figu
ure below. It
I is usually
y used for shafts
s
less than
t
about 60 mm dia
ameter and the
ke
eyway is cu
ut in the shaft using a milling cuttter, as shown in the figure
f
below
w. It is wid
dely
ussed in mach
hine tools and
a
automo
obiles due tto the extra
a advantag
ge derived from
f
the ex
xtra
deepth.
Figure- Woodruff
W
key
y
The main ad
dvantages of a woodruff key ar
re as follow
ws:
Page 14 of 263
Design of Joint
S K Mondals
Chapter 1
1. It accommodates itself to any taper in the hub or boss of the mating piece.
2. It is useful on tapering shaft ends. Its extra depth in the shaft prevents any tendency
to turn over in its keyway.
The main dis-advantages of a woodruff key are as follows:
1. The depth of the keyway weakens the shaft.
2. It can not be used as a feather.
Significantly lower stress concentration factors result from this type of key as compared to
parallel or tapered keys. A ball end mill can be used to make the circular key seat.
Splines
Splines are essentially stub by gear teeth formed on the outside of the shaft and on the inside
of the hub of the load-transmitting component. Splines are generally much more expensive to
manufacture than keys, and are usually not necessary for simple torque transmission. They
are typically used to transfer high torques. One feature of a spline is that it can be made
with a reasonably loose slip fit to allow for large axial motion between the shaft and
component while still transmitting torque. This is useful for connecting two shafts where
relative motion between them is common, such as in connecting a power takeoff (PTO) shaft of
a tractor to an implement.
Stress concentration factors are greatest where the spline ends and blends into the shaft, but
are generally quite moderate.
Page 15 of 263
Desig
gn of Joint
S K Mo
ondals
C
Chapter
r1
Page 16 of 263
Splines ca
an be thoug
ght of
as a series of axial
keyways with mating
m
keys ma
achined on
nto a
shaft.
provide a more
Splines p
uniform circumfereential
transfer oof torque to the
shaft than
n a key.
Design of Joint
S K Mondals
Chapter 1
Welded joints
A welded joint is a permanent joint which is obtained by the fusion of the edges of the two
parts to be joined together, with or without the application of pressure and a filler material.
The heat required for the fusion of the material may be obtained by burning of gas (in case of
gas welding) or by an electric arc (in case of electric arc welding). The latter method is
extensively used because of greater speed of welding.
Welding is extensively used in fabrication as an alternative method for casting or forging and
as a replacement for bolted and riveted joints. It is also used as a repair medium e.g. to reunite
metal at a crack, to build up a small part that has broken off such as gear tooth or to repair a
worn surface such as a bearing surface.
Page 17 of 263
Desig
gn of Joint
S K Mo
ondals
C
Chapter
r1
(b
b) Butt Joints
Formed by
b placing the
t plates edge to edgee and weldin
ng them. G
Grooves are sometimes cut
(for thick
k plates) on the edges before
b
weld
ding. Accord
ding to the shape of th
he grooves, the
butt jointts may be off different ty
ypes, e.g.
Squarre butt jointt
Singlee V-butt join
nt, double V-butt
V
joint
Singlee U-butt join
nt, double U-butt
U
joint
Singlee J-butt join
nt, double J--butt joint
Singlee bevel-butt joint, double bevel buttt joint.
Th
hese are sch
hematically shown in fiigure below
Page 18 of 263
Des
sign of
o Join
nt
S K Monda
M
als
Chapte
er 1
Weldin
ng sym
mbol
A welding symbol hass following basic
b
elemen
nts:
1. Reference
R
line.
2. Arrow.
A
3. Basic
B
weld symbols
s
(lik
ke fillet, butt joints etc.))
4. Dimensions
D
5. Supplement
S
tary symbols.
6. Finish
F
symb
bols
7. Tail.
T
8. Specification
S
n processes
These welding symbols are placeed in standa
ard locationss (see figuree below)
Page 19 of 263
Desig
gn of Joint
S K Mo
ondals
C
Chapter
r1
Design
D
of a bu
utt joint
Th
he main faiilure mechanism of wellded butt joint is tensille failure. T
Therefore the strength of
o a
bu
utt joint is
Where
W
P = t t
t =th
hickness of the
t weld
l =len
ngth of the weld.
Foor a square butt joint t is equal too the thickn
ness of the plates.
p
In geeneral, this need not bee so
(ssee figure beelow).
Page 20 of 263
Des
sign of
o Join
nt
S K Monda
M
als
Chapte
er 1
Figu
ure- butt jointt
Design
n of tra
ansvers
se fillet joint
Consider a single tran
nsverse join
nt as shown
n in figure below.
b
The g
general stre
ess distributtion in
the weld metal
m
is very
y complicated. In desig
gn, a simple procedure is used assu
uming that entire
load P acts as shear force
f
on the
e throat area
a, which is the smallesst area of th
he cross secttion in
a fillet weld. If the filllet weld ha
as equal basse and heigh
ht, (h, say), then the crross section of the
e
seen to
t be
throat is easily
hl
2
. With
W
the aboove consideration the p
permissible load carried by a
transverse
e fillet weld is
Where s = allowablee shear stresss
P = s .Athroaat
Athroat = th
hroat area.
For a doub
ble transverrse fillet join
nt the allow
wable load iss twice that of the singlle fillet jointt.
Figu
ure- Enlarge view of filllet welding
Design
n of parallel fillet join
nt
Consider a parallel filllet weld as shown in fiigure below. Each weld
d carries a lo
oad P 2 . It is
i easy
to see from
m the streng
gth of materrial approacch that the maximum
m
sshear occurss along the throat
area (try to
t prove it).. The allowable load ca
arried by ea
ach of the joint
throat area At =
lh
. The
T total alllowable load
d is P = 2 s At.
2
Page 21 of 263
is
s At
, wheere the
Desig
gn of Joint
S K Mo
ondals
C
Chapter
r1
In
n designing a weld join
nt the desig
gn variables are h and l. They can
n be selected
d based on the
ab
bove design
n criteria. When
W
a comb
bination of ttransverse and paralleel filled joint required (see
(
fig
gure below) the allowab
ble load is
P = 2 s At + s At
Where
W
Figure
Design
D
of circu
ular fille
et weld
d subjec
cted to torsion
n
Consider a circular
c
sha
aft connecteed to a platte by meanss of a fillet joint as sh
hown in fig
gure
beelow. If the shaft is sub
bjected to a torque, sheear stress develops
d
in the
t weld in
n a similar way
w
ass in paralleel fillet join
nt. Assumin
ng that the weld thick
kness is verry small com
mpared to the
diiameter of the
t shaft, th
he maximum
m shear strress occurs in the throa
at area. Thus, for a giv
ven
toorque the maximum she
ear stress in
n the weld is
i
d
T + tthroat
2
max =
Jp
Where
W
T = torque app
plied.
d = outer diameter
d
off the shaft
t
thickn
ness
t throat = throat
Jp
4
( d + 2t throat ) d4
32
Page 22 of 263
Des
sign of
o Join
nt
S K Monda
M
als
When
t thhroat
Chapte
er 1
d, max =
d
2
tthroat d
2T
tthroat d 2
2T
tthroaat d 2
= max
m
Fig.
Q.
A pllate 50 mm
m wide an
nd 12.5 mm
m thick is to be welded to an
nother pla
ate by
means of para
allel fillet welds.
w
The
e plates are
e subjected
d to a load
d of 50 kN.. Find
the length
l
of th
he weld. Assume
A
allo
owable she
ear strengtth to be 56 MPa.
a loa
ad of P =
25 103 2
= 50
0.5mm . How
wever somee extra len
ngth of the weld is to
o be provid
ded as
1
103
56 12.5
allow
wance for sttarting or stopping
s
of the bead. A usual allowance of 12.5 mm iss kept.
(Note
e that the allowance ha
as no connecction with th
he plate thiickness)
Q.
00 mm wiide and 10
0 mm thic
ck are to be welded by mea
ans of
Two plates 20
nsverse wellds at the ends. If th
he plates ar
re subjecte
ed to a loa
ad of 70 kN
N, find
tran
the size
s
of the weld assum
ming the a
allowable tensile
t
stre
ess 70 MPa
a.
Solution: According to the design principlee of fillet (transverse) joint the weld is dessigned
ming maxim
mum shear stress occu
urs along th
he throat arrea. Since teensile stren
ngth is
assum
speciified the she
ear strength
h may be ca
alculated ass half of ten
nsile streng
gth, i.e. , s = 35
MPa. Assuming there are tw
wo welds, eeach weld ca
arries a load
d of 35 kN and
a the size of the
weld is calculate
ed from
10
1 10 3
35 103 = l
3 106
35
2
Or l = 141.42 m
mm.
Page 23 of 263
Design of Joint
S K Mondals
Chapter 1
Adding an allowance of 12.5 mm for stopping and starting of the bead, the length of the
weld should be 154 mm.
Q.
Solution. According to the procedure for calculating strength in the weld joint,
2T
tthroat d 2
= s
Where the symbols have usual significance. For given data, the throat thickness is 6.8
mm. Assuming equal base and height of the fillet the minimum size is 9.6 mm. Therefore
a fillet weld of size 10 mm will have to be used.
Q.
Fig.
Solution. As shown in the figure the joint is a parallel fillet joint with leg size as 9 mm and
the welding is done on both sides of the strap. Hence the total weld length is 2(50) = 100
mm.
In order to calculate the design stress the following data are used
k1 = 2.7 (parallel fillet joint, refer table 3) (there is required a table to solve the
problem)
w = 0.9 cm
K = -1 for completely reversed loading
The value of the allowable fatigue stress (assuming the weld to be a line) is then
1 =
358 0.9
= 214.8 kgf/cm = 214800 N/m
1.5
(approx).The
Page 24 of 263
design
stress
is
Therefore
Des
sign of
o Join
nt
S K Monda
M
als
1, d =
Chapte
er 1
214800
e the totall length off the weld
d is 0.1 m,
m the max
ximum
= 79556 N/m . Since
2..7
fluctuating
g load allow
wable for thee joint is 795
55.6 N. Thee joint is theerefore safe.
Thread
ded fas
steners
Bo
olt - Threa
aded fasten
ner designeed to pass
th
hrough holes in mating
g members and to be
seecured by tightening
t
a nut from
m the end
op
pposite the head
h
of the bolt.
Fig.
Sc
crew - Thrreaded fasttener desig
gned to be
in
nserted throough a holee in one meember and
in
nto a threadeed hole in a mating meember.
Fig.
Bolts
Machine Scre
ews
Page 25 of 263
Desig
gn of Joint
S K Mo
ondals
C
Chapter
r1
Sheet
S
M
Metal
an
nd Lag Screws
S
s
F
Figure-Sheet
t metal screews are often
n self-tapping.
Thread
T
Profiles
s
Th
he pitch line or diameter is located
d at the h
height of the
e theoreticall sharp v-th
hread profilee.
Thread
T
Series
Thread Seriies - groupss of diamete
er-pitch com
mbinations distinguishe
d
ed from eacch other by the
nu
umber of th
hreads per in
nch applied to a specificc diameter.
Page 26 of 263
Design of Joint
S K Mondals
Chapter 1
M-Series
Metric system of diameters, pitches, and tolerance/allowances.
ave
At =
F
=
At
F Axial Force
Dr Root Diameter
Dr + Dp
Dp Pitch Diameter
At Tensile Stress Area
ave Average axial stress
t =
Where
Fmax
At
0.5 t =
Fmax
As,i Le
Fmax = t At = 0.5 t As ,i Le
Le =
2 At
As,i
Page 27 of 263
Design of Joint
S K Mondals
Chapter 1
Keys
GATE-1. Square key of side "d/4" each and length l is used to transmit torque "T"
from the shaft of diameter "d" to the hub of a pulley. Assuming the length
of the key to be equal to the thickness of the pulley, the average shear
stress developed in the key is given by
[GATE-2003]
4T
16T
8T
16T
(a)
(b) 2
(c) 2
(d) 3
ld
ld
ld
d
GATE-1. Ans. (c) If a square key of sides d/4 is used then. In that case, for shear failure we
d d
have l x = T
4 2
8T
or x = 2
[Where x is the yield stress in shear and l is the key length.]
ld
GATE-2. A key connecting a flange coupling to a shaft is likely to fail in[GATE-1995]
(a) Shear
(b) tension
(c) torsion
(d) bending
GATE-2. Ans. (a) Shear is the dominant stress on the key
Welded joints
GATE-3. A 60 mm long and 6 mm thick fillet weld carries a steady load of 15 kN
along the weld. The shear strength of the weld material is equal to 200
MPa. The factor of safety is
[GATE-2006]
(a) 2.4
(b) 3.4
(c) 4.8
(d) 6.8
GATE-3. Ans. (b)
Strength of material
Factorofsafety =
Actual load or strength on material
200(in MPa)
200(in MPa)
=
= 3.4
3
58.91(in MPa)
15 10
6
60
106 (in MPa)
cos 45o
Threaded fasteners
Page 28 of 263
Design of Joint
S K Mondals
Chapter 1
GATE-4. A threaded nut of M16, ISO metric type, having 2 mm pitch with a pitch
diameter of 14.701 mm is to be checked for its pitch diameter using two or
three numbers of balls or rollers of the following sizes
[GATE-2003]
(b) Rollers of 1.155 mm
(a) Rollers of 2 mm
(c) Balls of 2 mm
(d) Balls of 1.155 mm
GATE-4. Ans. (b)
Cotters
Assertion (A): A cotter joint is used to rigidly connect two coaxial rods carrying
tensile load.
Reason (R): Taper in the cotter is provided to facilitate its removal when it fails
[IES-2008]
due to shear.
(a) Both A and R are true and R is the correct explanation of A
(b) Both A and R are true but R is NOT the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-1. Ans. (b) A cotter is a flat wedge shaped piece of rectangular cross-section and its
width is tapered (either on one side or both sides) from one end to another for an
easy adjustment. The taper varies from 1 in 48 to 1 in 24 and it may be increased up
to 1 in 8, if a locking device is provided. The locking device may be a taper pin or a
set screw used on the lower end of the cotter. The cotter is usually made of mild
steel or wrought iron. A cotter joint is a temporary fastening and is used to connect
rigidly two co-axial rods or bars which are subjected to axial tensile or compressive
forces.
IES-1.
IES-2.
Match List I with List II and select the correct answer using the code given
below the Lists:
[IES 2007]
List I
List II
(Application)
(Joint)
A. Boiler shell
1. Cotter joint
B. Marine shaft coupling
2. Knuckle joint
C. Crosshead and piston road
3. Riveted joint
D. Automobile gear box
4. Splines
(gears to shaft)
5. Bolted Joint
Code:
A
B
C
D
A
B
C
D
(a)
1
4
2
5
(b)
3
5
1
4
(c)
1
5
2
4
(d)
3
4
1
5
IES-2. Ans. (b)
IES-3.
Match List-I (Parts to be joined) with List-II (Type of Joint) and select the
correct answer using the code given below:
[IES-2006]
List-I
List -II
A. Two rods having relative axial motion
1. Pin Joint
B. Strap end of the connecting rod
2. Knuckle Joint
C. Piston rod and cross head
3. Gib and Cotter Joint
D. Links of four-bar chain
4. Cotter Joint
A
B
C
D
A
B
C
D
(a) 1
3
4
2
(b)
2
4
3
1
Page 29 of 263
Desig
gn of Joint
S K Mo
ondals
(c)) 1
IE
ES-3. Ans. (d)
(
C
Chapter
r1
3
(d)
IE
ES-4.
Ma
atch List I with List II and sele
ect the cor
rrect answe
er.
Liist I (Types
s of joints)
Listt II (An element of th
he joint)
A. Riveted jo
oint
1. Pin
B. Welded jo
oint
2. Sttrap
C. Bolted joiint
3. Lo
ock washe
er
D.. Knuckle joint
j
4. Fillet
C
D
A
Codes: A
B
B
C
D
2
3
1
(b)
2
3
4
(a)) 4
1
3
2
4
(c)) 2
4
1
(d)
1
3
IE
ES-4. Ans. (c)
(
[IES-199
94]
IE
ES-5.
[IES-200
06]
In
n a gib and cotter join
nt, the gib and cotter
r are subje
ected to
(a)) Single shear only
(b) doublle shear onlly
(c)) Single shea
ar and crush
hing
(d) doublle shear and
d crushing
IE
ES-5. Ans. (d)
(
IE
ES-6.
Ma
atch List I (Items in
n joints) w
with List III (Type of failure) an
nd select the
t
co
orrect answ
wer using the
t
codes given
g
below
w the Listss:
[IES-2004]
Liist I
L
List
II
A. Bolts in bolted
b
join
nts of engin
ne
1.Doubletra
ansverse sh
hear
cylinder cover platte
B. Cotters in
n cotter joiint
2. Torsional shear
C Rivets in lap
l
joints
ansverse sh
hears
3 Single tra
D.. Bolts hold
4. Tension
ding two fllanges in
a flange coupling
c
C
A
B
D
B
C
D
A
(a)) 4
3
1
2
(b)
4
2
3
1
4
1
(c)) 3
1
2
(d)
3
2
4
ES-6. Ans. (a)
(
IE
In
n a cotter joint, the width of the cotter
r at the ce
entre is 50
0 mm and its
th
hickness is
s 12 mm. The
T
load a
acting on the
t
cotter
r is 60 kN.. What is the
t
sh
hearing str
ress develo
oped in the
e cotter?
[IES-200
04]
(a)) 120 N/mm
m2
(b) 100 N/m
mm2
(cc) 75 N/mm2
(d)) 50 N/mm2
IE
ES-7. Ans. (d)
(
It is
i a case of double
d
shea
ar.
IE
ES-7.
Shear streess =
Load
60 103
= 50N / mm2
=
2 Area
a 2 50 12
2
Page 30 of 263
Design of Joint
S K Mondals
IES-8.
Chapter 1
The spigot of a cotter joint has a diameter D and carries a slot for cotter.
The permissible crushing stress is x times the permissible tensile stress for
the material of spigot where x > 1. The joint carries an axial load P. Which
one of the following equations will give the diameter of the spigot?
[IES-2001]
2P
P x 1
P x +1
2 P x +1
x +1
(b) D = 2
(d) D =
(c) D =
(a) D = 2
t
t x
t x
t x
Match List-l (Machine element) with List-II (Cause of failure) and select
the correct answer using the codes given below the lists:
[IES-1998]
List-I
List-II
A. Axle
1. Shear stress
B. Cotter
2. Tensile/compressive stress
C. Connecting rod
3. Wear
D. Journal bearing
4. Bending stress
Code:
A
B
C
D
A
B
C
D
(a)
1
4
2
3
(b)
4
1
2
3
(c)
4
1
3
2
(d)
1
4
3
2
IES-9. Ans. (b)
IES-10.
The piston rod and the crosshead in a steam engine are usually connected
by means of
[IES-2003]
(a) Cotter joint (b) Knuckle joint
(c) Ball joint
(d) Universal joint
IES-10. Ans. (a)
IES-11.
Match List I with List II and select the correct answer using the codes
given below the lists:
[IES-1995]
List I
List II
(Different types of detachable joints) (Specific use of these detachable joints)
A. Cotter joint
1. Tie rod of a wall crane
B. Knuckle joint
2. Suspension bridges
C. Suspension link joint
3. Diagonal stays in boiler
D. Turn buckle (adjustable joint)
4. Cross-head of a steam engine
Codes:
A
B
C
D
A
B
C
D
(a)
4
2
3
1
(b)
4
3
2
1
(c)
3
2
1
4
(d)
2
1
4
3
Page 31 of 263
Desig
gn of Joint
S K Mo
ondals
C
Chapter
r1
IE
ES-12. Ans.. (a)
IE
ES-13.
Ma
atch List I with Lisst II and select
s
the correct an
nswer usin
ng the cod
des
giv
ven below the lists:
[IES-1993]
List I (Ty
ype of jointt)
A. Cotter joint
B. Knuckle joint
C. Turn buck
kle
D.. Riveted jo
oint
List II (M
Mode of join
nting mem
mbers)
1. Connects two rods or
o bars per
rmitting sm
mall amoun
nt of flexib
bility
2. Rigidly co
onnects two memberss
3. Connects two rods having
h
thre
eaded ends
4. Permanen
nt fluid-tight joint be
etween two
o flat piece
es
5. Connects two shaftss and transsmits torqu
ue
C
D
Co
odes:
A
B
C
D
A
B
3
4
(a)
5
1
3
2
(b)
2
1
1
4
(c)
5
3
2
4
(d)
2
3
IE
ES-13. Ans. (b) A cotter is a flat wedge-shap
ped piece of steel. This is used to connect
c
rigiidly
wo rods whicch transmit motion in tthe axial dirrection, with
hout rotation. These joiints
tw
ma
ay be subjeccted to tensiile or comprressive force
es along thee axes of thee rods.
Coonnection off piston rod to the crosss-head of a steam engin
ne, valve rood and its sttem
etcc are examp
ples of cotterr joint.
IE
ES-14.
Asssertion (A
A): When th
he coupler oof a turn bu
uckle is turned in one direction both
b
the connectin
ng rods eith
her move closer or mov
ve away froom each oth
her depend
ding
up
pon the direcction of rota
ation of the coupler.
[IES-199
96]
Re
eason (R): A turn bucckle is used
d to connectt two round
d rods subje
ected to tensile
loa
ading and reequiring sub
bsequent ad
djustment foor tightenin
ng or looseniing.
(a)) Both A and
d R are indiividually tru
ue and R is the correct explanation
n of A
(b)) Both A and
d R are indiividually tru
ue but R is not
n the corrrect explana
ation of A
(c)) A is true but R is falsee
(d)) A is false but
b R is truee
IE
ES-14. Ans.. (b)
Fig. Tu
urnbuckle
Keys
K
IE
ES-15.
In
n the assem
mbly of pulley, key an
nd shaft
[IES-1993; 199
98]
(a)) pulley is made
m
the weeakest
(b) key iss made the weakest
Page 32 of 263
Des
sign of
o Join
nt
S K Monda
M
als
Chapte
er 1
IES-18.
A spur ge
ear transm
mitting pow
wer is con
nnected to
o the shaftt with a k
key of
rectangullar section
n. The type (s) of stressses develo
oped in the
e key is far
re.
(a) Shear stress
s
alone
(b) beearing stresss alone
[IES--1995]
(c) Both sh
hear and bea
aring stressees
(d) sh
hearing, bearing and beending stresses.
IES-18. Ans.
A
(c) Key
y develops booth shear an
nd bearing stresses.
s
Assertion (A): The effect of keeyways on a shaft is to reduce its load carrying
capacity an
nd to increase its torsioonal rigidity
y.
[IES--1994]
Reason (R
R): Highly lo
ocalized streesses occur at or near tthe corners of keyways..
(a) Both A and R are individually
y true and R is the correect explanattion of A
(b) Both A and R are individually
y true but R is not the ccorrect explanation of A
(c) A is true but R is fa
alse
(d) A is falsse but R is true
t
A
(d)
IES-19. Ans.
IES-19.
Page 33 of 263
Design of Joint
S K Mondals
Chapter 1
IES-20.
Which key is preferred for the condition where a large amount of impact
torque is to be transmitted in both direction of rotation?
[IES-1992]
(a) Woodruff key (b) Feather key
(c) Gib-head key
(d) Tangent key
IES-20. Ans. (d)
IES-21.
Page 34 of 263
Des
sign of
o Join
nt
S K Monda
M
als
Chapte
er 1
IES-26.
A pulley is connec
cted to a power tra
ansmission
n shaft of diameter d by
means of a rectangu
ular sunk k
key of wid
dth wand le
ength l. The
T
width of
o the
key is tak
ken as d/4.. For full p
power tran
nsmission, the shear
ring streng
gth of
the key is
s equal to the
t
torsion
nal shearin
ng strength
h of the sha
aft. The ra
atio of
the length
h of the key to the diameter of the shaft ((l/d) is
[IES--2003]
(c)
(d)
(a)
(b)
4
2
2
IES-26. Ans.
A
(c)
d
Shearing strength of key:F
k
= . .l
4
T) =F.
Torque(T
d
d d
= . .l .
2
4 2
Torsional shearing,
=
4
d
d
2
32
16
For samee strength
or T = d3
d d
. .l . = d3
2
16
4
l
or =
d 2
Assertion (A): A Woo
odruff key iss an easily adjustable
a
k
key.
Reason (R
R): The Woo
odruff key a
accommodattes itself to any taper in the hub oor boss
of the matiing piece.
[IES--2003]
(a) Both A and R are individually
y true and R is the correect explanattion of A
(b) Both A and R are individually
y true but R is not the ccorrect explanation of A
(c) A is true but R is fa
alse
(d) A is falsse but R is true
t
A
(b)
IES-27. Ans.
IES-27.
a
of a woodru
uff key are as
a follows:
The main advantages
1. It accom
mmodates itsself to any taper in the hub or bosss of the mating piece.
2. It is usefful on taperring shaft en
nds. Its extrra depth in the
t shaft prrevents any
tendency too turn over in its keywa
ay.
The main dis-advanta
d
ages of a wooodruff key are
a as follow
ws:
1. The deptth of the key
yway weakeens the shafft.
2. It can noot be used as
a a feather.
Page 35 of 263
Design of Joint
S K Mondals
IES-28.
Chapter 1
[IES-2000]
Match List I (Keys) with List II (Characteristics) and select the correct
answer using the codes given below the Lists:
[IES-2000]
List I
List II
A. Saddle key
1. Strong in shear and crushing
B. Woodruff key
2. Withstands tension in one direction
C. Tangent key
3. Transmission of power through frictional
resistance
D. Kennedy key
4. Semicircular in shape
Code:
A
B
C
D
A
B
C
D
(a)
3
4
1
2
(b)
4
3
2
1
(c)
4
3
1
2
(d)
3
4
2
1
IES-29. Ans. (d)
IES-30.
Match List-I with List-II and select the correct answer using the code
given below the Lists: [IES-2009]
List-I
List-II
(Description)
(shape)
A. Spline
1. Involute
B. Roll pin
2. Semicircular
C. Gib-headed key
3. Tapered on on side
D. Woodruff key
4. Circular
Code:
A
B
C
D
A
B
C
D
(a)
1
3
4
2
(b)
2
3
4
1
(c)
1
4
3
2
(d)
2
4
3
1
IES-30. Ans. (c)
IES-31.
The shearing area of a key of length 'L', breadth 'b' and depth 'h' is equal to
(a) b x h
(b) Lx h
(c) Lx b
(d) Lx (h/2)
[IES-1998]
IES-31. Ans. (c)
Splines
IES-32.
Page 36 of 263
[IES-1998]
Design of Joint
S K Mondals
Chapter 1
Welded joints
IES-33.
[IES-2002]
IES-34.
A single parallel fillet weld of total length L and weld size h subjected to a
tensile load P, will have what design stress?
[IES 2007]
P
P
(b) Tensile and equal to
(a) Tensile and equal to
0.707Lh
Lh
P
P
(d) Shear and equal to
(c) Shear and equal to
0.707Lh
Lh
IES-34. Ans. (c)
Throat, t = h cos450 =
IES-35.
1
h = 0.707h
v2
P
P
T=
=
Lt
0.707Lh
[IES-1997]
P
2P
( c ) t = ( d )t =
2hl
Hl
Page 37 of 263
Design of Joint
S K Mondals
IES-37.
Chapter 1
A double fillet welded joint with parallel fillet weld of length L and leg B is
subjected to a tensile force P. Assuming uniform stress distribution, the
[IES-1996]
shear stress in the weld is given by
2P
B.L
IES-38. Ans. (c)
(a)
IES-39.
(b)
2.B.L
(c)
P
2.B.L
(d)
2P
B.L
Page 38 of 263
Design of Joint
S K Mondals
=
Chapter 1
P1
A1
P1 = A1
P1 = t I1
P2 = t I2
P1 y1 = P2 y 2
tI1 y1 = tI2 y 2
I1 y1 = I2 y 2
IES-41.
[IES-2005]
or l = 200
IES-42.
Shear fore = W dt
Torque ( T ) = W dt
d
d 2
.tW
=
2
2
IES-43.
Page 39 of 263
Design of Joint
S K Mondals
Chapter 1
N/mm2.
IES-44.
Threaded fasteners
IES-45.
(c)
2F
dh
(d )
F
dh
[IES-1997]
Assertion (A): Uniform-strength bolts are used for resisting impact loads.
Reason (R): The area of cross-section of the threaded and unthreaded parts is
made equal.
[IES-1994]
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-47. Ans. (c) A is true and R is false.
IES-48.
Page 40 of 263
[IES-1992]
(d) 8
Design of Joint
S K Mondals
Chapter 1
Page 41 of 263
2.
Couplings
Introduction
Couplings are used to connect two shafts for torque transmission in varied applications. It may
be to connect two units such as a motor and a generator or it may be to form a long line shaft
by connecting shafts of standard lengths say 6-8m by couplings. Coupling may be rigid or they
may provide flexibility and compensate for misalignment. They may also reduce shock loading
and vibration. A wide variety of commercial shaft couplings are available ranging from a
simple keyed coupling to one which requires a complex design procedure using gears or fluid
drives etc.
Rigid couplings.
Flexible couplings.
Rigid couplings are used for shafts having no misalignment while the flexible couplings
can absorb some amount of misalignment in the shafts to be connected. In the next
section we shall discuss different types of couplings and their uses under these two broad
headings.
Page 42 of 263
Sleeve coupling
One of the simple types of rigid coupling is a sleeve coupling which consists of a cylindrical
sleeve keyed to the shafts to be connected. A typical sleeve coupling is shown in figure below
di
d0
=
And for safety
L
b 2 r
Page 43 of 263
br =
b L
2 2 r
sleeve =
shaft =
16Td0
(d d
4
0
4
i
and
the
shear
stress
in
the
shaft
is
given
by
16T
. Substituting yield shear stresses of the sleeve and shaft materials for
di3
Page 44 of 263
2 d
2 dmean
2 = T .
4
Here T is the torque and the shear stress must not exceed the shear yield stress of the pin
material. A suitable factor of safety may be used for the shear yield stress.
Clamp coupling
A typical clamp coupling is shown in figure below. It essentially consists of two half cylinders
which are placed over the ends of the shafts to be coupled and are held together by through
bolt.
Page 45 of 263
T =
dL
2
d
2
L1 = 3d
L2 = 3.5d + 12.7 mm
L3 = 1.5d
Oldham coupling
These couplings can accommodate both lateral and angular misalignment to some extent.
An Oldham coupling consists of two flanges with slots on the faces and the flanges are keyed
or screwed to the shafts. A cylindrical piece, called the disc, has a narrow rectangular raised
portion running across each face but at right angle to each other. The disc is placed between
the flanges such that the raised portions fit into the slots in the flanges. The disc may be made
of flexible materials and this absorbs some misalignment. A schematic representation is
shown in figure below.
Page 46 of 263
Figure- A schematic
s
diiagram of an
n Oldham ccoupling
Figure- -U
Universal jooints (or Hoookes or) cou
upling
Design
n proce
edures for rig
gid and flexiblle rubb
ber-bushed
coupliings
Flange couplin
ng
It is a verry widely used
u
rigid coupling
c
and
d consists of
o two flang
ges keyed to
t the shaftts and
bolted. Th
his is illustra
ated in figurre below.
Page 47 of 263
Desig
D
n of F
Frictio
on Driv
ves
S K Mo
ondals
C
Chapter
r2
Figu
ure- A typica
al flange cou
upling
eatures of the
t
design
n are essentially
The main fe
(a
a) Design of bolts.
(b
b) Design of hub.
(c) Overall deesign and diimensions.
Rigid
R
Flange Couplin
C
g
A typical rigiid flange cou
upling is sh
hown in Figu
ure above. If
I essentiallly consists of
o two cast iron
fla
anges which
h are keyed
d to the sha
afts to be jooined. The flanges
f
are brought tog
gether and are
boolted in the annular space between
n the hub an
nd the proteecting flang
ge. The proteective flang
ge is
prrovided to guard
g
the projecting
p
bolt heads and
a
nuts. Th
he bolts aree placed equ
ui-spaced on a
boolt circle dia
ameter and
d the numbeer of bolt depends on the
t
shaft diiameter d. A spigot A on
on
ne flange an
nd a recess on
o the oppossing face is provided for ease of assembly.
Th
he design procedure
p
is
i generally
y based on determinin
ng the shaft
ft diameter d for a giv
ven
toorque transsmission an
nd then foollowing em
mpirical rellations diffeerent dime
ensions of the
co
oupling are obtained. Check for different fa
ailure modees can then
n be carrieed out. Dessign
prrocedure is given in the
e following steps:
s
(1
1) Shaft diam
meterd bassed on torqu
ue transmisssion is giveen by
1/3
1
16T
d=
Where
W
T is th
he torque an
nd y is the yield
y
stress in shear.
(2
2) Hub diam
meter, d1 =1.75d
=
+ 6.5
5 mm
Page 48 of 263
d
. In that case, for shear failure
4
d
d
4 k y 2=T
This gives
8T
Lk = 2
d y
If Lk determined here is less than hub length L we may assume the key length to be the same
as hub length.
d
d
16T
c =
Lkd 2
And if c < cy , the bearing strength of the key material ,the key dimensions chosen are in
order.
= n
db2 yb
dc
2
Where n is the number of bolts, db nominal bolt diameter, T is the torque transmitted, yb is
the shear yield strength of the bolt material and dc is the bolt circle diameter. The bolt
Page 49 of 263
n=
4
d+3
150
Where d is the shaft diameter in mm. The bolt circle diameter must be such that it should
provide clearance for socket wrench to be used for the bolts. The empirical relation takes care
of this.
Considering crushing failure we have
= n.dbt2 cyb
dc
2
Where t2 is the flange width over which the bolts make contact and cyb is the yield crushing
strength of the bolt material. This gives t2. Clearly the bolt length must be more than 2 t2 and
a suitable standard length for the bolt diameter may be chosen from hand book.
(6) A protecting flange is provided as a guard for bolt heads and nuts. The thickness t3 is less
t
than 2 the corners of the flanges should be rounded.
2
(7) The spigot depth is usually taken between 2-3mm.
(8) Another check for the shear failure of the hub is to be carried out. For this failure mode we
may write
d1
= d1t2 yf
2
Where d1 is the hub diameter and yf is the shear yield strength of the flange material.
Knowing yf we may check if the chosen value of t2 is satisfactory or not.
Finally, knowing hub diameter d1, bolt diameter and protective thickness t2
We may decide the overall diameter d3.
Page 50 of 263
(1) Bea
aring stress
Rubber bu
ushings aree available for differen
nt inside an
nd out side diameters. However rubber
r
bushes are
e mostly ava
ailable in th
hickness bettween 6 mm
m to 7.5 mm
m for bores upto
u
25 mm and 9
mm thickn
ness for larrger bores. Brass sleev
ves are ma
ade to suit the requireements. How
wever,
brass sleev
ve
Thickness may be tak
ken to be 1.5
5mm. The outside diam
meter of rubb
ber bushing
g dr is given by
dr = db +2 tbr +2 tr
Where db is
i the diameter of the bolt
b
or pin, tbr is the th
hickness of the
t brass slleeve and tr is the
thickness of rubber bu
ushing. We may now w
write
Page 51 of 263
n.drt2 pb
dc
=T
2
Where dc is the bolt circle diameter and t2 the flange thickness over the bush contact area. A
suitable bearing pressure for rubber is 0.035 N/mm2 and the number of pin is given by
n=
d
+3
25
where d is in mm.
The dc here is different from what we had for rigid flange bearings. This must be judged
considering the hub diameters, out side diameter of the bush and a suitable clearance. A rough
drawing is often useful in this regard.
From the above torque equation we may obtain bearing pressure developed and compare this
with the bearing pressure of rubber for safely.
b =
pbt2dr
2
dneck
Where dneck is bolt diameter at the neck i.e. at the shear plane.
Bending Stress
The pin loading is shown in Figure below.
Page 52 of 263
b =
3
32 F (t 2 / 2 )
dbr3r
Knowing the
t shear an
nd bending stresses wee may check
k the pin dia
ameter for principal
p
sttresses
using apprropriate the
eories of faillure.
We may allso assume the followin
ng empiricall relations:
meter = 2d
Hub diam
Hub lengtth = 1.5d
0.5
5d
n
Page 53 of 263
Design a typical rigid flange coupling for connecting a motor and a centrifugal
pump shafts. The coupling needs to transmit 15 KW at 1000 rpm. The allowable
shear stresses of the shaft, key and bolt materials are 60 MPa, 50 MPa and 25
MPa respectively. The shear modulus of the shaft material may be taken as
84GPa. The angle of twist of the shaft should be limited to 1 degree in 20 times
the shaft diameter.
d=
16T
stress in shear.
15 103
2 N
Here T = Power /
= 143 Nm
=
60 2 1000
60
T G
=
J
L
Substituting T = 143Nm, J =
32
( 0.025 )
= 38.3 10 9 m4 ,G = 84 109 Pa
143
38.3 109 84 109
Which is
180
= 0.035 radian per meter
20 0.025
Hub
Page 54 of 263
Hub thickness, t1 =
Key
Now to avoid the shear failure of the key (refer to Figure above)
d
d
d
L
4 k y 2 = T , Where the key width w = 4 and the key length is L
This gives Lk =
8T
( d )
2
i.e.
8 143
50 106 ( 0.025 )
= 0.0366 m = 36.6 mm
d d
= Lk
8 2
16T
This gives =
Lkd 2
Substituting T = 143Nm, Lk = 37.5 x 10-3 m and d = 0.025 m
16 143 10 6
37.5 10 3 ( 0.025 )
= 97.62 MPa
Assuming an allowable crushing stress for the key material to be 100MPa, the key design is
safe. Therefore the key size may be taken as: a square key of 6.25 mm size and 37.5 mm long.
However keeping in mind that for a shaft of diameter between 22mm and 30 mm a
rectangular key of 8mm width, 7mm depth and length between 18mm and 90mm is
Page 55 of 263
Bolts
To avoid shear failure of bolts
=n
db2 yb
dc
2
n=
4
d+3
150
8T
db =
n d
yb c
1
2
8 143
2
= 7.48 103
i.e.
3
6
4 25 10 65 10
ndbt2 c
dc
2
Substituting n=4, db=10mm, c=100MPa, dc=65mm & T = 143Nm and this gives t2 = 2.2mm.
However empirically we have t2
1
t1 + 6.5 = 13 mm
2
Page 56 of 263
1
t2 we thereforre take t3 = 8mm since
e there
2
is no direcct load on th
his part.
Spigott depth
h
Spigot dep
pth which iss mainly proovided for loocation may
y be taken ass 2mm.
Check
k for the
e shearr failure
e of the
e hub
To avoid shear failuree of hub we have
T = d1t2 f
d1
2
Substitutiing d1 = 51m
mm, t2 = 13m
mm and T = 143Nm, wee have shearr stress in flange
fl
f as
f =
2T
d12t2
Figu
ure- A typical pin for th
he bushings
There is an enlarged portion on which
w
a flex
xible bush iss fitted to ab
bsorb the misalignmen
m
nt. The
threaded portion
p
prov
vided for a nut to tightten on the flange.
f
Considering thee whole pin
n there
are three basic stressses developeed in the piin in additio
on to the tig
ghtening sttresses. Theere are
(a) shear stresses
s
at the
t unthrea
aded neck arrea (b) bend
ding stress oover the loa
aded portion
n (L) of
the enlarg
ged portion of
o the pin an
nd (c) bearin
ng stress.
However, before we consider
c
the
e stresses we
w need to determine
d
tthe pin diam
meter and leength.
Here the torque
t
transsmitted
Page 57 of 263
50 103
= 159Nm
2 3000
60
16T
=
d
( )
y
1
3
Substituting T=159Nm and y = 60MPa, we have d = 23.8mm. Let the shaft diameter be
25mm. From empirical relations we have
Pin diameter at the neck ,
( dneck ) =
0.5d
n
4d
Where the number of pins, ( n ) =
+3
150
Substituting d = 25 mm we have
n = 3.67 (say) 4
dneck = 6.25 (say) 8mm
T
dc
2
4 dneckn 2
T = npLdbush
Page 58 of 263
dc
2
POWER SCREW
Introduction
A power screw is a drive used in machinery to convert a rotary motion into a linear motion for
power transmission. It produces uniform motion and the design of the power screw may be
such that
(a) Either the screw or the nut is held at rest and the other member rotates as it moves
axially. A typical example of this is a screw clamp.
(b) Either the screw or the nut rotates but does not move axially. A typical Example for this is
a press.
Other applications of power screws are jack screws, lead screws of a lathe, screws for
vices, presses etc.
Power screw normally uses square threads but ACME or Buttress threads may also be used.
Power screws should be designed for smooth and noiseless transmission of power with an
ability to carry heavy loads with high efficiency. We first consider the different thread forms
and their proportions:
Square threads
The thread form is shown in figure below. These threads have high efficiency but they are
difficult to manufacture and are expensive. The proportions in terms of pitch are:
h1= 0.5 p; h2 = 0.5 p - b; H = 0.5 p + a; e = 0.5 p
Page 59 of 263
Desig
D
n of F
Frictio
on Driv
ves
S K Mo
ondals
C
Chapter
r2
Acme
A
or Trape
ezoidal threads
Th
he Acme th
hread form is shown in
n figure below. These threads
t
ma
ay be used in
i applications
su
uch as lead screw of a lathe where loss of motiion cannot be
b tolerated
d. The includ
ded angle
=
290
a=
and oth
her proportioons are
p
2.7
An
nd h = 0.25
5 p + 0.25 mm
m
Page 60 of 263
Buttre
ess thre
ead
This threa
ad form can
n also be used for poweer screws bu
ut they can
n transmit power
p
only in one
direction. Typical app
plications arre screw jack
k, vices etc.
A Buttresss thread forrm is shown
n in figure b
below, and the proporttions are shown in the figure
in terms of the pitch.
On the whole the sq
quare threa
ads have th
he highest efficiency
e
as compared
d to other thread
t
forms but they are less sturdy th
han the trap
pezoidal thrread forms a
and the adjustment forr wear
is difficultt for square threads.
When a la
arge linear motion
m
of a power
p
screw
w is required
d two or moore parallel threads aree used.
These are called multtiple start power drivess.
Page 61 of 263
Desig
D
n of F
Frictio
on Driv
ves
S K Mo
ondals
C
Chapter
r2
Efficien
E
cy of a Powerr screw
w
A square thread power screw
s
with a single sta
art is shown
n in figure below.
b
Here p is the pittch,
the helix angle,
a
dm the
e mean diam
meter of thrread and F is the axial load. A de
eveloped sin
ngle
th
hread is shoown in figurre below wh
here L = n p for a mullti-start driv
ve, n being the numberr of
sttarts. In ord
der to analyzze the mech
hanics of thee power screew we need to consider two cases:
(a
a) Raising the
t
load
(b
b) Lowerin
ng the load
d.
Raising
R
the loa
ad
Th
his requiress an axial fo
orce P as sh
hown in figu
ure below. Here
H
N is the normal reeaction and N
is the friction
nal force.
Page 62 of 263
This gives
N = W / ( cos - sin )
P=
W ( cos + sin )
( cos sin )
Where
P= Effort applied at the circumference
of the screw to lift the load.
W= load to be lifted.
= coefficient of friction (tan),
where is friction angle
= helix angle
p= pitch of the screw
TR = P
dm
d ( cos + sin )
=W m
2
2 ( c os sin )
Since, tan =
TR = W
L
we have
dm
dm ( dm + L )
2 ( dm L )
The force system at the thread during lowering the load is shown in figure below. For
equilibrium
P - N cos + N sin = 0
W
F - N cos - N sin = 0
This gives
N = W / ( cos + sin )
P=
W ( cos sin )
( c os + sin )
TL = P
dm
d ( cos sin )
=W m
2
2 ( c os + sin )
Page 63 of 263
L
we have
dm
dm ( dm L )
2 ( dm + L )
TL = F
d m < L
d m L
W ork output
W ork input
P. d m
=
W
tan
P
The above analysis is for square thread and for trapezoidal thread some modification is
required. Because of the thread angle the force normal to the thread surface is increased as
shown in figure below. The torque is therefore given by
T =W
dm ( dm sec + L )
2 ( dm L sec )
This considers the increased friction due to the wedging action. The trapezoidal threads are
not preferred because of high friction but often used due to their ease of machining.
Page 64 of 263
FigureF
Norrmal force on a trapezoidal thread surface
Bursting effe
ect on the nut
Bursting effect
e
on th
he nut is ca
aused by thee horizontal componen
nt of the ax
xial load F on
o the
screw and this is give
en by (figuree above)
Fx = F tan
n
For an ISO
O metric nu
ut 2 = 600 and
a Fx = 0.57
777 F.
Collarr friction
n
If collar frriction c is considered then anotheer term Fd
dc/2 must bee added to torque expreession.
Here dc iss the effective friction diameter oof the colla
ar. Thereforre we may write the torque
t
required to raise the load
l
as
T =W
dm + L )
dm (
d
+ cW c
2 ( dm L )
2
Proble
ems witth Solu
ution
Q.
Page 65 of 263
Desig
D
n of F
Frictio
on Driv
ves
S K Mo
ondals
C
Chapter
r2
Figure- C- Clamp
So
olution: (a)) Nominal diameter
d
of the
t screw, ((d) = 10 mm
m.
Piitch of the screw,
s
(p) = 2 mm.
Ch
hoosing a sq
quare screw
w thread we have the foollowing dim
mensions:
Root diamete
er, (d3) = dnominal - 2h3 = 7.5 mm (sin
nce ac = 0.25
5 mm and
h3=0.5p + ac)
Piitch diameter, d2 = dnom
m (since z = 0.5 p)
minal -2z = 8 mm.
Mean
M
diametter, dm = (7.5+8)/2 = 7.7
75 mm.
Toorque,
T =F
dm + L )
dm (
d
+ c F c
2 ( dm L )
2
Here
H
F = 700
0 N, = c = 0.15, L = p = 2 mm (asssuming a single start screw
s
threa
ad) and dc = 16
mm.
m This giv
ves T = 1.48 Nm.
Equating thee torque required and th
he torque ap
pplied by th
he handle off length L we
w have 1.48
8=
15
5 L since the assumed handle
h
forcee is 15 N.
Th
his gives L=
= 0.0986 m. Let the han
ndle length be 100 mm..
Th
he maximum
m bending stress
s
that may
m be deveeloped in th
he handle is
My 32
2M
=
Where d is the diameter of thee handle.
d3
I
Ta
aking the alllowable ben
nding stresss as 165 MP
Pa we have
32 M
d=
y
1/3
1/3
2 1.48
32
=
6
165 10
With
W
a higheer factor of safety
s
let d = 10 mm.
Q.
Q
A sing
gle square
e thread po
ower screw
w is to raise a load off 50 KN. A screw thre
ead
of ma
ajor diame
eter of 34 mm and a pitch of 6 mm is u
used. The coefficient
c
t of
friction at the thread an
nd collar a
are 0.15 an
nd 0.1 respectively. If the colllar
frictional diame
eter is 100 mm and th
he screw turns
t
at a sspeed of 1 rev s-1 find
d
(a) Th
he power input to the screw.
(b) Th
he combine
ed efficien
ncy of the sscrew and collar.
So
olution: (a) Mean diam
meter, dm = dmajor p/2 = 34-3 = 31 mm.
Page 66 of 263
= 416 Nm
Power input = T = 416 x 2 x 1 = 2613.8 Watts.
(b) The torque to raise the load only (T0) may be obtained by substituting = c= 0 in the
torque equation. This gives
T0 = F
Therefore =
dm L FL 50 103 0.006
=
= 47.75
=
2 dm 2
2
FL / 2
47.75
=
= 0.1147 i.e.11.47%
T
416
Clutches
Introduction of Friction clutches
A Clutch is a machine member used to connect the driving shaft to a driven shaft, so that the
driven shaft may be started or stopped at will, without stopping the driving shaft. A clutch
thus provides an interrupt tible connection between two rotating shafts.
Clutches allow a high inertia load to be stated with a small power.
Mechanical Model
Two inertias and I1and I2 traveling at the respective angular velocities 1 and 2, and one of
which may be zero, are to be brought to the same speed by engaging. Slippage occurs because
the two elements are running at different speeds and energy is dissipated during actuation,
resulting in temperature rise.
Page 67 of 263
Desig
D
n of F
Frictio
on Driv
ves
S K Mo
ondals
C
Chapter
r2
Fig
gure- Dynam
mic Represeentation of Clutch
C
or Brrake
FRICTIO
F
ON CLU
UTCHES
S
As in brakes a wide ran
nge of clutch
hes are in u
use wherein
n they vary
y in there arre in use th
heir
working
w
prin
nciple as well
w
the meethod of acttuation and
d applicatioon of norm
mal forces. The
T
diiscussion heere will be limited
l
to mechanical
m
ttype friction
n clutches or
o more spe
ecifically to the
pllate or disc clutches
c
alsso known ass axial clutch
hes
Friction
F
al Conttact axiial or D
Disc Clu
utches
An axial clutch is one in which the mating
m
fricttional memb
bers are mooved in a dirrection para
allel
too the shaft. A typical clutch
c
is illlustrated in
n the figure
e below. It consists of a driving disc
d
co
onnected to the drive sh
haft and a driven
d
disc connected to
t the driven
n shaft. A friction
f
plate is
atttached to one
o
of the members. Actuating
A
sspring keep
ps both the members in
i contact and
a
poower/motion
n is transmiitted from one
o memberr to the otheer. When th
he power of motion
m
is too be
in
nterrupted the
t driven disc
d
is moveed axially crreating a ga
ap between the members as shown
n in
th
he figure bellow.
Page 68 of 263
Fig.
METHOD OF ANALY
YSIS
The torque
e that can be
b transmittted by a clutch is a function of its g
geometry an
nd the magn
nitude
of the actu
uating force applied as well the con
ndition of co
ontact preva
ailing betwe
een the mem
mbers.
The applieed force can
n keep the members
m
together with
h a uniform pressure alll over its contact
area and the
t consequent analysiss is based on
n uniform pressure
p
con
ndition.
Page 69 of 263
Desig
D
n of F
Frictio
on Driv
ves
S K Mo
ondals
C
Chapter
r2
Torque
T
e transm
mitting
g capa
acity
Uniform
U
m pressure the
eory
However
H
as the
t time progresses some wear ta
akes place between
b
thee contacting
g members a
and
th
his may alteer or vary th
he contact pressure
p
app
propriately and uniform
m pressure condition may
m
no
o longer preevail. Hencee the analysis here is ba
ased on unifform wear ccondition.
Element
E
tary An
nalysis
Assuming un
niform presssure and con
nsidering an
n elementall area dA
dA = 2
.r dr
Th
he normal force
f
on thiss elemental area is
dN = 2
. r.dr.p
Th
he frictional force dF on
n this area is thereforee
dF = f.2
2.r.dr.p (f = co- efficie
ent of friction)
Th
he total torrque that coould be tran
nsmitted is obtained by
b integratin
ng this equ
uation between
th
he limits of inner
i
radius ri to the outer radiu
us ro .
Page 70 of 263
2
T = 2 pfr 2dr = pf r03 ri3
3
ri
Integrating the normal force between the same limits we get the actuating force that need to
be applied to transmit this torque.
r0
Fa = 2 prdr
ri
Fa = r02 ri2 . p
Equation 1 and 2 can be combined together to give equation for the torque
T = fFa
2 (r
3 (r
3
0
ri3
2
0
ri2
)
)
ri ,
K = pmax ri
Hence pressure at any point in the contact region
p = pmax
ri
r
In the previous equations substituting this value for the pressure term p and integrating
between the limits as done earlier we get the equation for the torque transmitted and the
actuating force to be applied.
I.e. The axial force Fa is found by substituting p = pmax
And integrating equation dN = 2prdr
Page 71 of 263
ri
for p.
r
Desig
D
n of F
Frictio
on Driv
ves
S K Mo
ondals
C
Chapter
r2
r0
r0
ri
ri
Siimilarly thee Torque
T =
r0
f 2 p
2
2
rrdrr = f pmax
m ri r0 ri
max i
ri
Su
ubstituting the values of actuating
g force Fa
Th
he equation
n can be give
en as
T = fFa
r0 + ri )
(
Single
S
p
plates
dry
d Cluttch A
Automottive app
plicatio
on
Th
he clutch used in automotive appllications is generally a single platte dry clutcch. In this ty
ype
th
he clutch pla
ate is interp
posed betweeen the flywheel surfacee of the engiine and pressure plate..
gure
Fig
Single
S
C
Clutch
and
a Mu
ultiple D
Disk Clu
utch
Basically, the
e clutch nee
eds three pa
arts. These are
a the engiine flywheel, a friction disc called the
clutch plate and
a a pressu
ure plate. When
W
the en
ngine is runn
ning and th
he flywheel is
i rotating, the
prressure platte also rotattes as the prressure platte is attacheed to the fly
ywheel. The friction dissc is
lo
ocated between the tw
wo. When th
he driver ha
as pushed down the clutch
c
pedal the clutch
h is
re
eleased. Thiis action forrces the preessure platee to move aw
way from th
he friction disc.
d
There are
Page 72 of 263
Multip
ple Plate
e Clutc
ches
Fig. Multip
ple Plate Clu
utches
The properties of the frictional lining are im
mportant factors in the d
design of th
he clutches
Opera
ation of Clutch
h
When the driver releases the clu
utch pedal, power can flow throug
gh the clutcch. Springs in the
clutch forcce the presssure plate against
a
thee friction dissc. This acttion clampss the friction
n disk
tightly bettween the fllywheel and
d the pressu
ure plate. Now,
N
the preessure plate
e and frictioon disc
rotate with
h the flywhe
eel.
As both sid
de surfaces of the clutcch plate is u
used for tran
nsmitting th
he torque, a term N is added
to include the numberr of surfacess used for trransmitting
g the torque.
By rearra
anging the terms the equations ccan be mod
dified and a more gen
neral form of the
equation can
c be written as
T=N
N.f.Fa.R
Rm
Where
T = the torrque (Nm).
N = the nu
umber of frictional discs in contactt.
f = the coe
efficient of frriction
Fa = the acctuating forrce (N).
Rm = the mean
m
or equ
uivalent radius (m).
Note that
Where
N = n1 + n 2 - 1
d
n1 = numberr of driving discs.
n2 = number of driven diiscs.
Page 73 of 263
Clutch Construction
Two basic types of clutch are the coil-spring clutch and the diaphragm-spring clutch. The
difference between them is in the type of spring used. The coil spring clutch shown in left
figure below uses coil springs as pressure springs (only two pressure springs is shown). The
clutch shown in right figure below uses a diaphragm spring.
Fig.
The coil-spring clutch has a series of coil springs set in a circle.
Page 74 of 263
Cone clutche
c
es
At high ro
otational sp
peeds, problems can arise
a
with multi
m
coil spring clutch
hes owing to the
effects of centrifugall forces botth on the spring theemselves an
nd the leveer of the release
r
mechanism
m.
F
FigureConee clutches
These problems are obviated
o
wh
hen diaphra
agm type sp
prings are u
used, and a number off other
advantagees are also experienced.
e
.
Page 75 of 263
Desig
D
n of F
Frictio
on Driv
ves
S K Mo
ondals
C
Chapter
r2
Figure
e- cross secttion of cone clutch
Centrifu
C
ugal clu
utches
Th
he centrifugal clutche
es are usua
ally incorpoorated into the motor pulleys. Itt consists oof a
nu
umber of sh
hoes on thee inside of a rim of th
he pulley, as
a shown in
n figure bellow. The ou
uter
su
urface of the
e shoes is covered
c
with
h a friction material. These
T
shoes,, which can
n move radia
ally
in
n guides, are held again
nst the boss (or spiderr) on the driiving shaft by means of
o springs. The
T
sp
prings exertt a radially inward forcce which is assumed
a
con
nstant. Thee weight of the
t shoe, wh
hen
re
evolving cau
uses it to ex
xert a radia
ally outward
d force (i.e. centrifugall force). The
e magnitudee of
th
his centrifu
ugal force depends
d
up
pon the speed at wh
hich the sh
hoe is revollving. A little
co
onsideration
n will show that when the centrifu
ugal force iss less than the spring force, the sh
hoe
re
emains in the same position
p
as when the driving sh
haft was stationary, but when the
ce
entrifugal fo
orce is equa
al to the sp
pring force, the shoe iss just floatiing. When the
t
centrifu
ugal
fo
orce exceedss the spring force, the shoe
s
moves outward an
nd comes intto contact with
w
the driv
ven
member
m
and
d presses ag
gainst it. The
T
force with which the
t
shoe prresses again
nst the driv
ven
member
m
is th
he differencce of the cen
ntrifugal foorce and thee spring forrce. The inccrease of speed
ca
auses the sh
hoe to press harder and
d enables moore torque to
t be transm
mitted.
Page 76 of 263
Energy Considerations
Kinetic energy is absorbed during slippage of a clutch and this energy appears as heat.
The clutch or brake operation is completed at the instance in which the two angular velocities
1 and 2 become equal. Let the time required for the entire operation be t1, then,
t1 =
I1 I 2 (1 2 )
T ( I1 + I 2 )
I1 1 = T
1 =
T
t + 1
I1
I 2 2 = T
2 =
T
t + 2
I2
= 1 2 =
T
t + 1 t + 2
I1
I2
I + I2
= 1 2 T 1
t
I
I
1 2
From which
t=
I1 I 2 (1 2 )
T ( I1 + I 2 )
Page 77 of 263
Desig
D
n of F
Frictio
on Driv
ves
S K Mo
ondals
C
Chapter
r2
E =
I1 I 2 (1 2 )
2 ( I1 + I 2 )
I + I2
U = T i = T 1 2 T 1
t
I1 I 2
t1
t1
I + I2
E = udt = T 1 2 T 1
t dtt
I
I
1 2
0
0
I1I2 ( 1 - 2 )
E=
2 ( I1 + I2 )
Th
hus the eneergy absorbe
ed during clutch
c
slip iss a function
n of the mag
gnitude of the
t inertia and
a
th
he angular velocities
v
on
nly. This energy compa
ared to the brake
b
energ
gy may be negligible. Heat
H
diissipation and
a
temperrature rise are govern
ned by the
e same equ
uations presented durring
brrakes. To co
ontain the teemperaturee rise when very frequeent clutching operations, wet clutches
ra
ather than dry
d clutchess are often use.
u
Friction
F
materiials and
d their propertties
Th
he most im
mportant meember in a mechanicall brake is the
t
friction material. A good fricttion
material
m
is reequired to possess
p
the following
f
prroperties:
High and reproduciblee coefficient of friction.
Impervioussness to env
vironmentall conditions..
Ability to withstand
w
hiigh tempera
ature (therm
mal stability
y)
High wear resistance.
Flexibility and conform
mability to any
a surface..
So
ome commoon friction materials are woven cotton liniing, woven asbestos lining,
l
mold
ded
assbestos linin
ng, molded asbestos
a
pad, Sintered metal padss etc.
WORKED
W
OUT
O
EXAM
MPLE 1
Design
D
an automotive
a
e plate cluttch to tran
nsmit a torq
que of 550 N-m. The coefficientt of
fr
riction is 0.25
0
and th
he permissible intenssity of pressure is 0.5 N/mm2. Due to spa
ace
limitations, the outer diameter of the fricttion disc iss fixed as 250
2 mm.
Page 78 of 263
Therefore two pairs of contacting surfaces-one between the fly wheel and the friction disc and
the other between the friction disc and the pressure plate. Therefore, the torque transmitted
by one pair of contacting surfaces is (550/2) or 275 N-m
( Tt )f
= pa ri r02 ri2
2
i
2
i
= 87.08 mm
(ii) ri = 56.145 mm
(iii) ri = -143.23 mm
Mathematically, all the three answer are correct. The inner radius cannot be negative. As a
design engineer, one should select the inner radius as 87.08 mm, which results in a minimum
area of friction lining compared with 56.145. For minimum cost of friction lining.
ri =87 mm
Actuating force needed can be determined using the equation
Fa = 2pa ri ( r0 ri ) = 2 ( 0.5 )( 87 )(125 87 ) = 10390.28 N
Page 79 of 263
ri
2
2
N = T / pmaxrf
i r0 ri = 6.69
Since N must be an even integer, use N= 8. It is evident that this requires a total of 4+5, or
nine discs, remembering that the outer disks have friction surfaces on one side only. 3. With
no other changes, this will give a clutch that is over designed by a factor of 8/6.69= 1.19.
Possible alternatives include (a) accepting
the 19 percent over design, (b) increasing ri , (c) decreasing ro , and (d) leaving both radii
unchanged and reducing both pmax and F by a factor of 1.194. With the choice of alternative d,
the clamping force is computed to be just sufficient to produce the desired torque:
r +r
0.050 + 0.029
T = Ff 0 i N = 85 N .m = F ( 0.06 )
8,
2
2
F = 4483 N
Rounding up the calculated value of F, we
Find that the final proposed answers are (a) inside diameter= 58 mm, (b)
Clamping force= 4500 N and (C) a total of nine discs.
Page 80 of 263
Fig
gure- Crosseed or twist belt
b drive.
F
FigureNon
n reversing open
o
belt
F
FigureRev
versing crossed belt.
Crossed belts musst be separa
ated to preveent
Rubbin
ng if high-friction materrials are used.
Page 81 of 263
Desig
D
n of F
Frictio
on Driv
ves
S K Mo
ondals
C
Chapter
r2
Figurre- Reversin
ng open-beltt drive.
F
FigureBelt drive with many idler pulleys
elt drive; an
n idler guidee pulley musst be Used if
i motion is to be in both
Fiigure- Quarrter-twist be
Direction.
Length
L
of the belt
b
Page 82 of 263
( r1 + r2 ) + 2x +
( 1 r2 )2
(r
x
(d d2 )
( d1 + d 2 ) + 2x + 1
4x
2
...(in terms
t
of pullley radius)
2
ulley diameteers)
...(in terms of pu
(d + d )
( d1 + d2 ) + 2xx + 1 2
2
4x
Belt te
ension
T1 = Tensiion in the be
elt on the tight side,
T2 = Tensiion in the be
elt on the sllack side, an
nd
Page 83 of 263
Desig
D
n of F
Frictio
on Driv
ves
S K Mo
ondals
C
Chapter
r2
= Angle off contact in radians (i.e. angle subttended by th
he arc AB,
Along which the bellt touches th
he pulley, a
at the centree).
T1
= e .
T2
Notes:
N
1. Wh
hile determiining the an
ngle of conta
act, it must be remembered that itt is the angle of
co
ontact at thee smaller pu
ulley, if both
h the pulley
ys are of thee same mateerial. We kn
now that
r1 r2
... ( for opeen belt drivee )
x
r +r
= 1 2
... ( for cross-beelt drive )
x
Angle of contact
c
or la
ap,
Power tra
ansmitted,,
P = (T1 T2) v
Centrifu
C
ugal ten
nsion
Siince the belt
b
continu
uously run
ns over th
he
pu
ulleys, therrefore, som
me centrifugal force is
i
ca
aused, whosse effect is to increase
e the tension
on
n both the tight
t
as welll as the slacck sides. Th
he
teension caussed by centtrifugal forrce is calleed
ce
entrifugal tension. At lower belt speeds (lesss
th
han 10m/s), the centrrifugal tenssion is verry
sm
mall, but at
a higher belt
b
speeds (more tha
an
10
0m /s), its effects is considerablle and thu
us
sh
hould be tak
ken into account.
Consider
C
a small poortion PQ of the bellt
su
ubtending an
a angle d
at the ceentre of th
he
pu
ulley, as sho
own in figurre.
Tc = Centrifu
ugal tension
n
m = Mass of belt
b per uniit length in kg,
v = Linear veelocity of bellt in m/s,
r = Radius off pulley overr which the belt runs in
n meters.
Tc = m.v2
When
n centrifugall tension is taken
t
into account,
a
the
en total tenssion in the tight
t
side,
Page 84 of 263
P = [(T1 + Tc ) (T2 + Tc )]v = (T1 T2) v ...(in watts) ... (same as before)
Thus we see that the centrifugal tension has no effect on the power transmitted.
The ratio of driving tensions may also be written as
T TC
log e t1
= .
Tt 2 TC
Where Tt1 = Maximum or total tension in the belt.
P = ( Tmax Tc ) 1 v
e
1
P = Tmax v mv 3 1
e
dP
= Tmax 3mv 2 = 0
dv
T
mv 2 = max
3
Tmax
Tc =
3
Tmax = 3Tc
Page 85 of 263
For similar materials having the same maximum permissible tension V-belt transmits
more power than flat belt with same velocity ratio and centre distance.
As two sides of V-belt are in contact with side faces of pulley groove, larger contact area
gives greater effective frictional force.
In a multiple V belt drive, when a single belt is damaged, it is preferable to change the
complete set to ensure uniform loading.
V-belt designation
B 2786 Gr50 standard size of belt
Type nominal
Of
inside
V belt length
Q.1.
Ans.
Q.2.
Why angle of wrap correction factor and belt length correction factor is
required to modify power rating of a belt?
The power rating of V-belts are based on angle of wrap, =1800 . Hence, for any angle
of wrap, other than 180, a correction factor is required. Similarly, if the belt length is
different from optimum belt length for which the power rating is given, then belt length
correction factor is used, because, amount of flexing in the belt in a given time is
different from that in optimum belt length.
Ans.
Q.3.
Ans.
Page 86 of 263
Let
T1 T0 = T0 T2
T0 =
T1 + T2
2
T1 + T2 + 2TC
2
T1 + T2 = 2 T0
Chain drive
Page 87 of 263
Desig
D
n of F
Frictio
on Driv
ves
S K Mo
ondals
C
Chapter
r2
Fig
gure- Sprockets and ch
hain.
Th
he chains are mostly used
u
to transsmit motion
n and powerr from one sshaft to anotther, when the
ce
entre distan
nce between
n their shaffts is shortt such as in
n bicycles, m
motor cyclees, agricultu
ural
machinery,
m
c
conveyors,
r
rolling
millss, road rolllers etc. Th
he chains m
may also be used for loong
ce
entre distan
nce of up to 8 metres. Th
he chains are used for velocities up to 25 m /ss and for pow
wer
up
p to 110kW. In some ca
ases, higher power tran
nsmission is also possib
ble.
Advanta
A
ages an
nd Disa
advanta
ages off Chain Drive over
o
Be
elt
or
o Rope
e Drive
Foollowing aree the advan
ntages and disadvantag
d
ges of chain drive over b
belt or rope drive:
Advantag
A
ges
1.. As no slip takes place during chain drive, heence perfect velocity rattio is obtain
ned.
2.. Since the chains
c
are made
m
of mettal, thereforre they occu
upy less spa
ace in width
h than a beltt or
ro
ope drive.
3.. It may be used
u
for botth long as well
w as short distances.
4.. It gives hig
gh transmisssion efficien
ncy (upto 98
8 percent).
5.. It gives lesss load on th
he shafts.
6.. It has the ability to transmit mottion to severral shafts by
y one chain only.
7.. It transmitts more pow
wer than bellts.
8.. It permits high speed ratio of 8 to
o 10 in one sstep.
9.. It can be operated und
der adverse temperaturre and atmoospheric con
nditions.
Disadvan
D
ntages
1.. The producction cost off chains is relatively
r
hiigh.
e, particula
2.. The chain drive needss accurate mounting
m
an
nd careful maintenanc
m
arly lubricattion
an
nd slack adjjustment.
3.. The chain drive has velocity flucttuations esp
pecially wheen unduly sttretched.
Feature
F
s of chain driv
ve
Page 88 of 263
Roller chains are probably the most common and are used in a wide variety of lowspeed to high-speed drives.
Silent Chain: Silent (inverted-tooth) chains are standardized in for pitches of 0.375 to
2.0 in. Silent chain is an assembly of toothed link plates interlaced on common pins.
The sprocket engagement side of silent chain looks much like a gear rack. Silent chains
are designed to transmit high power at high speeds smoothly and relatively quietly.
Silent chains are a good alternative to gear trains where the center distance is too long
for one set of gears.
Chains can span long center distances like belts, and positively transmit speed and
torque like gears.
For a given ratio and power capacity, chain drives are more compact than belt drives,
but less compact than gear drives.
Mounting and alignment of chain drives does not need to be as precise as for gear
drives. Chain drives can operate at 98 to 99 percent efficiency under ideal conditions.
Chain drives are usually less expensive than gear drives and quite competitive with
belt drives.
12 teeth
17 teeth
25 teeth
Given that P = chain pitch, c = centre distance, N and n = number of teeth on large and
small sprocket respectively, the length of chain in terms of pitches can be approximated
by
2c
P
+ ( N + n) / 2 P + [( N n) / 2 P ]2
P
c
Speed Ratio. The maximum recommended speed ratio for a single-reduction rollerchain drive is 7:1. Speed ratios up to 10:1 are possible with proper design, but a double
reduction is preferred.
For roller chain drive with sprocket having z teeth, the velocity of the driven shaft with
respect to that of drive will be approximately
(V
max
180
Vmin ) 1 cos
In order to reduce the variation in chain speed, the number of teeth on the sprocket
should be increased. It has been observed that the speed variation is 4% for a sprocket
with 11 teeth, 1.6% fro a sprocket with 24 teeth.
For smooth operation at moderate and high speeds, it is considered a good practice to
use a driving sprocket with at least 17 teeth. For durability and noise considerations,
the minimum number of teeth on the driving sprocket should be 19 or 21.
Page 89 of 263
Chain Length: Required chain length may be estimated from the following
approximate equation:
N1 + N 2 N1 N 2
2C +
+
2
4 2C
Where
L = Chain length, in chain pitches
N = Number of teeth on small sprocket
N1 = Number of teeth on small sprocket
N2 = Number of teeth on large sprocket
C = Centre distance, in chain pitches
Vmax =
dN
60
m/s
Vmin =
dN cos / 2
60
m/s
Rope drive
The rope drives are widely used where a large amount of power is to be transmitted, from one
pulley to another, over a considerable distance.
It may be noted that the use of flat belts is limited for the transmission of moderate power
from one pulley to another when the two pulleys are not more than 8 meters apart.
If large amounts of power are to be transmitted, by the flat belt, then it would result in
excessive belt cross-section.
The ropes drives use the following two types of ropes:
1. Fibre ropes, and
2. Wire ropes.
The fibre ropes operate successfully when the pulleys are about 60 meters apart, while the
wire ropes are used when the pulleys are upto 150 meters apart.
Page 90 of 263
6 20 wire
w
rope: 6 indicates number
n
of sttrands in th
he wire ropee and 20 ind
dicates no off wire
in a strrand.
Creep of Beltt
When the belt passess from the sllack side to the tight siide, a certaiin portion of the belt ex
xtends
and it contracts again
n when the belt passess from the tight side too the slack side.
s
Due too these
here is a relative motioon between
n the belt an
nd the pullley surfacess. This
changes of length, th
m
is terrmed as cre
eep. The tottal effect off creep is to reduce slig
ghtly the sp
peed of
relative motion
the driven
n pulley or foollower. Con
nsidering crreep, the vellocity ratio is
i given by
N 2 d1 E + 2
=
N1 d2 E + 1
1 and 2 = Stress in the belt on
o the tightt and slack sside respecttively, and
E = You
ungs modullus for the material
m
of the
t belt.
Note: Sincce the effectt of creep is very small,, therefore it is generally neglected
d.
Where
Page 91 of 263
Desig
D
n of F
Frictio
on Driv
ves
S K Mo
ondals
C
Chapter
r2
Power
P
s
screw
For exam
mple, in the case
c
of the lead
l
screw oof lathe, the rotary motion is availa
able but thee
tool has too be advancced in the diirection of th
he cut again
nst the cutting resistan
nce of the
material.
In case off screw jack,, a small forrce applied iin the horizzontal planee is used to raise
r
or lower
a large load. Power screws
s
are also
a
used in vices, testin
ng machiness, presses, etc.
e
Power
P
S
Screw
(ii)
Fo
orms of thread
ds
Figu
ure Forms of
o threads
Page 92 of 263
tan =
dm
= ( numberr of s ta rts ) x p
( iii ) d m = d 0.5p
( iv ) d c = d p
W( cos + sin )
d
Square thread
(cos sin )
tan
( vi ) efficieency ( ) =
tan ( + )
( v ) Liffingg Load : ( P ) =
m if , = 45 / 2
( vii ) efficiiency will be max imum
max =
1 sin
1 + sin
h
angle
Figure; - Effiiciency Vs helix
When the helix angle further inccreases say 70o, the efficiency drops. This is du
ue to the facct that
the norma
al thread foorce becomes large and
d thus the force
f
of fricttion and thee work of frriction
become larrge as comp
pared with the
t useful w
work. This reesults in low
w efficiency..
3
3
WD d
p
th
heory.
( xi ) Collaar friction ( Mt )c = c 2 2c Uniform pressure
3 D dc
W
U
we
ear theory
y.
( Mt )c = c ( D + d c ) Uniform
4
( xii ) Totaal torque ( Tt ) = Mt + ( Mt )c
Wll
.
2Tt
Page 93 of 263
/ 4 d 2 d 2c z
W
dm t z
d 2 d 2c
d + dc d dc
P
=
= dm = dm t
4
2
2
2
N.B. In order to reduce wear of the screw and nut, the bearing pressure on the thread surface
must be with in limits. In the design of power screws, the bearing pressure depends upon the
materials of the screw and nut relative velocity between screw & nut and the nature of
lubrication. In actual practice, the core diameter is first obtained by considering the screw
under simple compression and then checked for critical load or buckling load for stability of
the screw.
Couplings
GATE-1. The bolts in a rigid flanged coupling connecting two shafts transmitting
power are subjected to
[GATE-1996]
(a) Shear force and bending moment (b) axial force.
(c) Torsion and bending moment
(d) torsion
Page 94 of 263
(
(
)
)
0.4 2 106
.p. D3 d 3 =
0.13 0.043 =196Nm
12
12
GATE-3. A disk clutch is required to transmit 5 kW at 2000 rpm. The disk has a
friction lining with coefficient of friction equal to 0.25. Bore radius of
friction lining is equal to 25 mm. Assume uniform contact pressure of 1
MPa. The value of outside radius of the friction lining is
[GATE-2006]
(a) 39.4 mm
(b) 49.5 mm
(c) 97.9 mm
(d) 142.9 mm
GATE-3. Ans.(a)
P 60
Torque,T =
= 23.87 N m
2 N
= Axial thrust,W = P (r12 r22 )
(r 3 r 3 )
2
P (r12 r22 ) 12 22 = wr
3
(r1 r2 )
But
T=
r2 = 39.4 mm
[GATE-1997]
Belt tension
GATE-5. The ratio of tension on the tight side to that on the slack side in a flat belt
drive is
[GATE-2000]
(a) Proportional to the product of coefficient of friction and lap angle
(b) An exponential function of the product of coefficient of friction and lap angle.
(c) Proportional to the lap angle
(d) Proportional to the coefficient of friction
GATE-5. Ans. (b)
T1
= 0
T2
Page 95 of 263
GATE-7. The percentage improvement in power capacity of a flat belt drive, when
the wrap angle at the driving pulley is increased from 150 to 210 by an
idler arrangement for a friction coefficient of 0.3, is
[GATE-1997]
(a) 25.21
(b) 33.92
(c) 40.17
(d) 67.85
GATE-7. Ans. (d) We know that Power transmitted (P) = ( T1 T2 ) .v W
Case-I:
5
6
0.3
T1
T
= e or 1 = e
T2
T2
or T1 = 2.193 T2 P1 = 1.193T2 V W
0.3
T
T
Case-II: 1 = e or 1 = e
T2
T2
or T1 = 3.003 T2 P1 = 2.003T2 V W
P2 P1
100% = 67.88 %
P1
Centrifugal tension
GATE-8. With regard to belt drives with given pulley diameters, centre distance
and coefficient of friction between the pulley and the belt materials, which
of the statement below are FALSE?
[GATE-1999]
(a) A crossed flat belt configuration can transmit more power than an open flat belt
configuration
(b) A "V" belt has greater power transmission capacity than an open flat belt
(c) Power transmission is greater when belt tension is higher due to centrifugal
effects than the same belt drive when centrifugal effects are absent.
(d) Power transmission is the greatest just before the point of slipping is reached
GATE-8. Ans. (c)
Rope drive
GATE-9. In a 6 20 wire rope, No.6 indicates the
[GATE-2003]
(a) diameter of the wire rope in mm
(b) Number of strands in the wire rope
(c) Number of wires
(d) Gauge number of the wire
GATE-9. Ans. (b) 6 20 wire rope: 6 indicates number of strands in the wire rope and 20
indicates no of wire in a strand.
Page 96 of 263
[GATE-1994]
Efficiency of screw
GATE-12. Which one of the following is the value of helix angle for maximum
[GATE-1997]
efficiency of a square threaded screw? [ = tan 1 ]
o
o
o
o
(b) 45 -
(c) 45 - /2
(d) 45 + /2
(a) 45 +
GATE-12. Ans. (c)
Couplings
IES-1.
Which of the following stresses are associated with the design of pins in
bushed pin-type flexible coupling?
[IES-1998]
1. Bearing stress
2. Bending stress
3. Axial tensile stress
4. Transverse shear stress
Select the correct answer using the codes given below
(a) 1, 3 and 4
(b) 2, 3 and 4
(c) 1, 2 and 3
(d) 1, 2 and 4
IES-2. Ans. (d)
IES-3.
Match List I with List II and select the correct answer using the codes
given below the lists:
[IES-1995]
List I
List II
A. Crank shaft
1. Supports the revolving parts and transmits torque.
B. Wire shaft
2. Transmits motion between shafts where it is not possible
to effect a rigid coupling between them
Page 97 of 263
B
2
2
IES-4.
[IES-2003]
IES-6.
Which one of the following pairs of parameters and effects is not correctly
matched?
[IES-1998]
(a) Large wheel diameter ..Reduced wheel wear
(b) Large depth of cut ...Increased wheel wear
(c) Large work diameter ...Increased wheel wear
(d) Large wheel speed ..Reduced wheel wear
IES-6. Ans. (d)
IES-7.
Two co-axial rotors having moments of inertia I1, I2 and angular speeds 1
and 2 respectively are engaged together. The loss of energy during
[IES-1994]
engagement is equal to
(a)
I1I2 ( 1 2 )
2 ( I1 + I2 )
(b)
I1I2 ( 1 2 )
2 ( I1 I2 )
(c)
2I1I2 ( 1 2 )
( I1 + I2 )
(d)
I112 I2 22
( I1 + I2 )
Page 98 of 263
(b) 1 and 3
(c) 2 and 4
(d) 1, 2, 3 and 4
IES-11.
Multi-disk clutches
IES-14.
In a multiple disc clutch if n1 and n2 are the number of discs on the driving
and driven shafts, respectively, the number of pairs of contact surfaces
will be
[IES-2001; 2003]
(a) n1 + n2
(b) n1 + n2 1
(c) n1 + n2 + 1
Page 99 of 263
(d)
n1 + n2
2
In the multiple disc clutch, If there are 6 discs on the driving shaft and 5
discs on the driven shaft, then the number of pairs of contact surfaces will
be equal to
[IES-1997]
(a) 11
(b) 12
(c) 10
(d) 22
IES-16. Ans. (c) No. of active plates = 6 + 5 - 1 = 10
Cone clutches
IES-17.
Which one of the following is the correct expression for the torque
transmitted by a conical clutch of outer radius R, Inner radius r and semicone angle assuming uniform pressure? (Where W = total axial load and
= coefficient of friction)
[IES-2004]
W(R + r)
W(R + r)
(a)
(b)
2sin
3sin
3
3
2W(R r )
3W(R3 r 3 )
(d)
(c)
2
2
3 sin (R r )
4 sin (R 2 r 2 )
IES-17. Ans. (c)
Centrifugal clutches
IES-18.
On the motors with low starting torque, the type of the clutch to be used is
(a) Multiple-plate clutch
(b) Cone clutch
[IES-2003]
(c) Centrifugal clutch
(d) Single-plate clutch with both sides
effective
IES-18. Ans. (c)
IES-19.
Match List-I with List-II and select the correct answer using the codes
given below the lists:
[IES-1998]
List-I
List-II
A. Single-plate friction clutch
1. Scooters
B. Multi-plate friction clutch
2. Rolling mills
C. Centrifugal clutch
3. Trucks
D. Jaw clutch
4. Mopeds
Code:
A
B
C
D
A
B
C
D
(a)
1
3
4
2
(b)
1
3
2
4
(c)
3
1
2
4
(d)
3
1
4
2
IES-20. Ans. (d)
Assertion (A): In pulley design of flat belt drive, the cross-sections of arms are
[IES-1999]
made elliptical with major axis lying in the plane of rotation.
Reason (R): Arms of a pulley in belt drive are subjected to torsional shear stresses
and are designed for torsion.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-23. Ans. (c)
IES-24.
Which one of the following belts should not be used above 40C? [IES-1999]
(a) Balata belt
(b) Rubber belt
(c) Fabric belt
(d) Synthetic belt
IES-24. Ans. (b)
IES-25.
In flat belt drive, if the slip between the driver and the belt is 1%, that
between belt and follower is 3% and driver and follower pulley diameters
are equal, then the velocity ratio of the drive will be
[IES-1996]
(a) 0.99
(b) 0.98
(c) 0.97
(d) 0.96.
IES-26. Ans. (d)
The length of the belt in the case of a cross-belt drive is given in terms of
centre distance between pulleys (C), diameters of the pulleys D and d as
(D + d )
(a) 2C + ( D + d ) +
2
4C
(D d )
(c) 2C + ( D + d ) +
2
4C
IES-28. Ans. (a)
(D + d )
(b) 2C + ( D d ) +
2
4C
(D d )
(d) 2C + ( D d ) +
2
4C
[IES-2002]
r +r
Lc = (r1 + r2 ) + 2C + 1 2
C
So length of crossed belt in constant. Both the statements are correct but Reason is
not the correct explanation of Assertion.
IES-30.
(r1
+ r2 ) 2
C
Belt tension
IES-31.
Assertion (A): In a short centre open-belt drive, an idler pulley is used to maintain
the belt tension and to increase the angle of contact on the smaller pulley.
In a Belt drive, if the pulley diameter is doubled keeping the tension and
[IES-1993]
belt width constant, then it will be necessary to
(a) Increase the key length
(b) increase the key depth
(c) Increase the key width
(d) decrease the key length
IES-32Ans. (c) Due to twice increase in diameter of pulley, torque on key is double and has to
be resisted by key width. Length can't be increased as belt width is same.
IES-33. The following data refers to an open belt drive:
[IES-1993]
Pulley A
Pulley B
Purpose .
Driving
Driven
Diameter
450 mm
750 mm
Angle of contact
A = 150o
A = 210o
Coefficient of friction between
f A = 0.36
f A = 0.22
belt and pulley
The ratio of tensions may be calculated using the relation (T1/T2) = exp (z)
where z is
(a) f A A
IES-33Ans. (a)
(b) f B B
(c) ( f A + f B )( A + B ) / 4
(d ) ( f A A + f B B ) / 2
T1
= e f A A where f and are taken for smaller pulley.
T2
Centrifugal tension
IES-34.
In the case of a vertical belt pulley drive with Tc as centrifugal tension and
To as the initial tension, the belt would tend to hang clear of the tower
pulley when
[IES-1997]
( a ) Tc < To
( b ) Tc < To / 3
(c)
Tc > To
( d ) Tc < To / 2
IES-35Ans. (c)
IES-36.
In case of belt drives, the effect of the centrifugal tension is to: [IES-2006]
(a) Cause the belt to leave the pulley and increase the power to be transmitted
(b) Cause the belts to stay on the pulley and increase the power to be transmitted
(c) Reduce the driving power of the belt
(d) Stretch the belt in longitudinal direction
IES-37Ans. (d) Centrifugal tension has no effect on the power to be transmitted.
In a flat belt drive the belt can be subjected to a maximum tension T and
centrifugal tension Tc . What is the condition for transmission of maximum
power?
[IES-2008]
(a) T=Tc
(b) T= 3 Tc
(c) T=2Tc
(d) T=3Tc
IES-38Ans. (d)
Condition for maximum power transmission:P = ( T1 T2 ) v
T1
= e
T2
P = ( Tmax Tc ) 1 v
e
1
P = Tmax v mv 3 1
e
dP
= Tmax 3mv 2 = 0
dv
T
mv 2 = max
3
Tmax
Tc =
3
=
Tmax 3Tc
IES-39.
Which one of the following statements with regard to belt drives is NOT
correct?
[IES-2000]
(a) Increase in the angle of wrap of the belt enables more power transmission
(b) Maximum power is transmitted when the centrifugal tension is three times the
tight side tension
(c) Wide and thin belt is preferable for better life than a thick and narrow one
(d) Crown is provided on the pulley to make the belt run centrally on the pulley
IES-39.Ans. (b)
IES-43.
Type nominal
of
inside
v belt length
[IES-2008]
Given that T1 and T2 are the tensions on the tight and slack sides of the
belt respectively, the initial tension of the belt taking into account
[IES-1997]
centrifugal tension Tc, is equal to
(a)
T1 + T2 + Tc
3
(b)
T1 + T2 + 2Tc
2
(c)
T1 + T2 + 3Tc
3
(d)
T1 T2 + 3Tc
3
IES-45Ans. (b)
Chain drive
IES-46.
Which one of the following drives is used for a constant velocity ratio,
positive drive with large centre distance between the driver and driven
shafts?
IES-2004]
(a) Gear drive
(b) Flat belt drive
(c) Chain drive
(d) V-belt drive
IES-46Ans. (c)
Assertion (A): Slider-crank chain is an inversion of the four-bar mechanism.
Reason(R): Slider-crank chain often finds applications in most of the reciprocating
[IES-2003]
machinery.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-47Ans. (b)
IES-47.
IES-48.
Match List I (Applications) with List II (Drive element) and select the
correct answer using the codes given below the Lists:
[IES-2000]
List I
A. Automobile differential
B. Bicycle
C. Planning machine
D. Radiator fan of automobile
Code:
A
B
C
(a)
4
3
1
(c)
4
2
1
IES-48Ans. (a)
D
2
3
List II
1. Flat belt
2. V-belt
3. Chain drive
4. Gear drive
A
B
(b)
1
3
(d)
1
2
C
4
4
D
2
3
IES-49.
(a)
IES-50Ans. (d)
IES-51.
2c
+ N + n) / 2
P
2c
P
(d)
+ ( N + n) / 2 P + [( N n) / 2 P ]2
P
c
(b)
For roller chain drive with sprocket having 10 teeth, the velocity of the driven
shaft with respect to that of drive will be approximately
[IES-2008]
(a) same
(b) 5% above
(c) 5% below
(d) 5% above to 5% below
IES-51Ans. (d)
( Vmax Vmin )
180
1 cos
In order to reduce the variation in chain speed, the number of teeth on the sprocket
should be increased. It has been observed that the speed variation is 4% for a
sprocket with 11 teeth, 1.6% fro a sprocket with 24 teeth.
For smooth operation at moderate and high speeds, it is considered a good practice
to use a driving sprocket with at least 17 teeth. For durability and noise
considerations, the minimum number of teeth on the driving sprocket should be 19
or 21.
Rope drive
In a 6 20 wire rope, No.6 indicates the
[IES- 2001; 2003; 2007]
(a) diameter of the wire rope in mm
(b) Number of strands in the wire rope
(c) Number of wires
(d) Gauge number of the wire
IES-52Ans. (b) 6 20 wire rope: 6 indicates number of strands in the wire rope and 20
indicates no of wire in a strand.
IES-52.
IES-53.
Assertion (A): In lifts, wire ropes are preferred over solid steel rods of same
diameter.
Reason (R): Wire ropes are more flexible than steel rods and also provide plenty of
time for remedial action before failure.
[IES-1999]
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
W Wr
f
g
( a ) Fa =
W + Wr
f
g
( b ) Fa =
( c ) Fa =
W
f
g
( d ) Fa =
Wr
f
g
IES-55Ans. (b)
IES-56.
Effective stress in wire ropes during normal working is equal to the stress
due to
[IES-1996]
(a) Axial load plus stress due to bending.
(b) Acceleration / retardation of masses plus stress due to bending.
(c) Axial load plus stress due to acceleration / retardation.
(d) bending plus stress due to acceleration/retardation.
IES-56Ans. (a)
IES-57.
When compared to a rod of the same diameter and material, a wire rope
(a) Is less flexible
[IES-1994]
(b) Has a much smaller load carrying capacity.
(c) Does not provide much warning before failure.
(d) Provides much greater time for remedial action before failure.
IES-57Ans. (d) A wire rope provides much greater time for remedial action before failure.
Power screws are used to produce uniform, slow and powerful motion
such as required in presses, jacks and other machinery. 'V' threads are
usually not used for this application due to low efficiency. This is because:
(a) Profile angle is zero
(b) Profile angle is moderate
[IES-2005]
(c) Profile angle is large
(d) There is difficulty in manufacturing the profile
IES-58.Ans. (c)
Square thread most efficient.
Profile angle is zero which causes
excessive bursting force.
IES-59.
While designing a screw in a screw jack against buckling failure, the end
[IES-1995]
conditions for the screw are taken as
(a) Both the ends fixed
(b) both the ends hinged
(c) One end fixed and other end hinged
(d) one end fixed and the other end
free.
IES-62Ans. (d) The screw is considered to be a strut with lower end fixed and load end free
Assertion (A): The load placed at the top of the screw in a mechanical screw jack
[IES-1993]
is prevented from rotation by providing a swivelling mechanism.
Reason (R): When the screw in a mechanical screw jack rotates, the load kept on
top of it moves axially up or down.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-63Ans. (d) In this case A is false but R is true.
IES-63.
IES-64.
[IES-1999]
Desig
D
n of F
Frictio
on Driv
ves
S K Mo
ondals
C
Chapter
r2
IE
ES-65.
Th
he load cup
p of a screw jack is m
made separate from the head of
o the spindle
to
[IES-199
95]
(a)) Enhance the load carrrying capaciity of the jack
(b)) Reduce thee effort need
ded for liftin
ng the work
king load
(c)) Reduce thee value of frrictional torq
que required to be coun
ntered for lifting the loa
ad
(d)) Prevent th
he rotation of
o load being
g lifted.
IE
ES-65Ans. (d)
(
IE
ES-66.
Un
nder servic
ce conditio
ons involviing jarring
g, vibration
n and pulssation of th
he
wo
orking load, the bolt of choice would
[IES 200
07]
(a)) short bolt with high riigidity
(b) long bolt
b with in
ncreased elasticity
(c)) Bolt with a dished washer
(d) bolt with
w
castle n
nut
IE
ES-66Ans. (d)
(
IE
ES-67.
If P is the piitch of a sq
quare threa
ad, then th
he depth off thread d is given by
y
(a)) 0.5 P
(b) P
(c) 1.5 P
(d) 2.0 P
IE
ES-67Ans. (a)
(
ES-68.
IE
Th
he friction
nal torque for square
e thread att mean rad
dius while
e raising lo
oad
is given by
[IES-199
93]
(W
W = load; Ro = Mean Radius;
R
= Angle of friction;
f
= Helix an
ngle)
(d ) WRo tan
IE
ES-68Ans. (b)
(
Self
S lock
king sc
crew
IE
ES-69.
Wh
hat is the efficiency
e
of a self-lo
ocking pow
wer screw?
[IES-2006; 199
97]
(a)) 70% (b) 60%
(c) 55%
(d) < 50 %
IE
ES-69Ans. (d) We knoow that thee frictional torque for square
s
threead at mean
n radius wh
hile
raiising load iss given by WR
W o tan( )
Wh
here: (W = load;
l
Ro = Mean R
Radius; = Angle of friction; = Helix ang
gle)
Foor self lockin
ng, angle of friction shoould be grea
ater than heelix angle off screw So that
W o tan( ) will becom
WR
me positive. i.e. we hav
ve to give torrque to loweering the loa
ad.
Efficiency of screw
IES-71.
1 tan( / 2)
1 + tan( / 2)
1 sin
(c)
1 + sin
(a)
1 tan
1 + tan
1 sin( / 2)
(d)
1 + sin( / 2)
(b)
IES-71Ans. (c)
IES-72.
1 sin
of a screw jack is same,
1 + sin
where is the friction angle, for both motion up and motion down the plane.
Reason (R): The condition for the maximum efficiency for motion up and motion
down the plane is same, given by =
[IES-2003]
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-72Ans. (a)
IES-73.
[IES-2002]
(d) 100%
IES-74.
Which one of the following is the value of helix angle for maximum
[IES-2004]
efficiency of a square threaded screw? [ = tan 1 ]
o
o
o
o
(b) 45 -
(c) 45 - /2
(d) 45 + /2
(a) 45 +
IES-74Ans. (c)
Collar friction
Stresses in a screw thread are estimated by considering the thread to be:
[IES-2006]
(a) Long cantilever beam projecting from the pitch cylinder
(b) Long cantilever beam projecting from the root cylinder
(c) Short cantilever beam projecting from the root cylinder
(d) Short cantilever beam projecting from the pitch cylinder
IES-75Ans. (c)
IES-75.
Q.20.
(a) WR
(b)
3
WR
4
(c)
2
WR
3
(d)
1
WR
2
T=
W
4
(D + d ), d = 0
and D = 2 R gives T =
R
2
[IAS-2001]
(d) sliding pair
Crushed ore is dropped on a conveyor belt at the rate of 300 kg/s. The belt
moves at speed of 2 m/s. The net force acting on the belt that keeps it
moving at the same speed is
[IAS-2001]
(a) 30 N
(b) 60 N
(c) 300 N
(d) 600 N
d
dm
( mv ) = v = 300 2 = 600 N
dt
dt
Belt tension
IAS-4. A Differential pulley is subjected
to belt tensions as shown in the
diagram. The resulting force
and moment when transferred
to the centre of the pulley are,
respectively
(a) 400 N and 0 Nm
(b) 400 N and 100 Nm
(c) 500 N and 0 Nm
(d) 500 N and 100 Nm
[IAS-2003]
IAS-4Ans. (c)
A 50 kW motor using six V belts is used in a pulp mill. If one of the belts
breaks after a month of continuous running, then
[IAS 1994]
Match List I with List II and select the correct answer using the code given
below the Lists:
[IAS-2007]
List I
List II
(Type of Thread)
(Use)
A. Square thread
1. Used in vice
B. Acme thread
2. Used in lead screw
C. Buttress thread
3. Used in screw jack
D. Trapezoidal thread 4. Used in power transmission devices in machine
tool
Code:
A
B
C
D
A
B
C
D
(a) 2
3
4
1
(b)
2
3
1
4
(c) 3
2
1
4
(d)
3
2
4
1
IAS-6Ans. (c)
S K Mondals
3.
Chapter 3
Design of Power
Transmission System
Theory at a glance (GATE, IES, IAS & PSU)
Spur gear
Basic Purpose of Use of Gears
Gears are widely used in various mechanisms and devices to transmit power
And motion positively (without slip) between parallel, intersecting (axis) or
Non-intersecting non parallel shafts,
Without change in the direction of rotation
With change in the direction of rotation
Without change of speed (of rotation)
With change in speed at any desired ratio
Often some gearing system (rack and pinion) is also used to transform Rotary motion into
linear motion and vice-versa.
A SPUR GEAR is cylindrical in shape, with teeth on the outer circumference that are
straight and parallel to the axis (hole). There are a number of variations of the basic spur
gear, including pinion wire, stem pinions, rack and internal gears.
Fig.
S K Mondals
Chapter 3
For a pair of meshing gears, the smaller gear is called the pinion, the larger is called the gear
wheel or simply the gear.
Pitch circle
S K Mondals
Chapter 3
This is a theoretical circle on which calculations are based. Its diameter is called the pitch
diameter.
d = mT
Where d is the pitch diameter (mm); m is the module (mm); and T is the number of teeth.
Care must be taken to distinguish the module from the unit symbol for a meter.
Circular pitch
This is the distance from a point on one tooth to the corresponding point on the adjacent tooth
measured along the pitch circle.
p = m =
d
T
Where p is the circular pitch (mm); m the module; d the pitch diameter (mm); and T the
Number of teeth.
Module.
This is the ratio of the pitch diameter to the number of teeth. The unit of the module should be
millimeters (mm). The module is defined by the ratio of pitch diameter and number of teeth.
Typically the height of a tooth is about 2.25 times the module. Various modules are illustrated
in figure.
m=
d
T
Addendum, (a). This is the radial distance from the pitch circle to the outside of the
tooth.
Dedendum, (b). This is the radial distance from the pitch circle to the bottom land.
Clearance (C) is the amount by which the dedendum in a given gear exceeds the addendum of its mating
gear.
Backlash
BACKLASH is the distance (spacing) between two mating gears measured at the back of the
driver on the pitch circle. Backlash, which is purposely built in, is very important because it
helps prevent noise, abnormal wear and excessive heat while providing space for lubrication of
the gears.
The backlash for spur gears depends upon (i) module and (ii) pitch line velocity.
S K Mondals
Chapter 3
Fig.
De
esign off Power Transm
mission S
System
S K Monda
M
als
Chapte
er 3
Figu
ure- Schema
atic of the in
nvolute form
m
Pitch Circle
C
a pitc
and
ch poin
nt
Fig.
Line of Action
A
Lin
ne tangent to both base circles
e line of cen
nters with th
he line of acction
Pitch Poiint Intersection of the
S K Mondals
Chapter 3
Fig.
Pitch Circle Circle with origin at the gear center and passing through the pitch point.
Fig.
S K Mondals
Chapter 3
Fig.
Pressure anglee Angle between the line normal to the line of centers and the line of action.
The value of pressure angle generally used for involute gears are 20
rb = r cos
Fig.
The following four systems of gear teeth are commonly used in practice.
S K Mondals
Chapter 3
1.
14 1
Composite system.
2.
14 1
3.
200
200
2
2
The 14 1 2 composite system is used for general purpose gears. It is stronger but has no
interchangeability. The tooth profile of this system has cycloidal curves at the top and bottom
and involute curve at the middle portion. The teeth are produced by formed milling cutters or
0
hobs. The tooth profile of the 14 1 2 full depth involute system was developed for use with
gear hobs for spur and helical gears.
The tooth profile of the 20 full depth involute system may be cut by hobs. The increase of
0
the pressure angle from 14 1 2 to 20 results in a stronger tooth, because the tooth acting as a
beam is wider at the base. The 20 stub involute system has a strong tooth to take heavy
loads.
Classification of Gears
Gears can be divided into several broad classifications.
1. Parallel axis gears:
(a) Spur gears
(b) Helical gears
(c) Internal gears.
2. Non-parallel, coplanar gears (intersecting axes):
(a) Bevel gears
(b) Face gears,
(c) Conical involute gearing.
3. Non-parallel, non- coplanar gears (nonintersecting axes):
(a) Crossed axis helical
(b) Cylindrical worm gearing
(c) Single enveloping worm gearing,
(d) Double enveloping worm gearing,
(e) Hypoid gears,
(f) Spiroid and helicon gearing,
(g) Face gears (off centre).
4. Special gear types:
(a) Square and rectangular gears,
(b) Elliptical gears.
RACK
Page 122 of 263
De
esign off Power Transm
mission S
System
S K Monda
M
als
Chapte
er 3
RACKS are
a yet anotther type off spur gear. Unlike thee basic spur gear, rackss have theirr teeth
cut into th
he surface off a straight bar instead
d of on the surface of a ccylindrical blank.
b
F
Fig. Rack
Helica
al gear
The helica
al gears ma
ay be of sin
ngle helica
al type or double
d
hellical type. In case of single
helical gea
ars there is some axial thrust betw
ween the teeeth, which is a disadvan
ntage. In orrder to
eliminate this axial thrust, dou
uble helicall gears (i.e. herringb
bone gearss) are used. It is
ngle helical gears, in which
w
equal and oppossite thrustss are provid
ded on
equivalentt to two sin
each gear and the ressulting axiall thrust is zero.
Herrin
ngbone gears
Herringbone gear
Figure-H
Des
sign of Power
P
Trransmis
ssion Sy
ystem
S K Mo
ondals
C
Chapter
r3
F
FigureHerrringbone geear
De
esign off Power Transm
mission S
System
S K Monda
M
als
Chapte
er 3
Bevel Gears
Fig.
Fig.
Worm Gear
Fig..
Fig.
d Gears
s
Hypoid
Hypoid geears resemble bevel gea
ars and spirral bevel gea
ars and aree used on crossed-axis shafts.
s
The distan
nce between
n a hypoid pinion axis and the ax
xis of a hyp
poid gear is called the offset.
Hypoid pin
nions may have
h
as few
w as five teeeth in a high
h ratio set. Ratios can be obtained
d with
hypoid gea
ars that are
e not availa
able with beevel gears. High ratioss are easy too obtain with the
hypoid gea
ar system.
S K Mondals
Chapter 3
Hypoid gears are matched to run together, just as zero or spiral bevel gear sets are matched.
The geometry of hypoid teeth is defined by the various dimensions used to set up the machines
to cut the teeth.
Hypoid gears are similar in appearance to spiral-bevel gears. They differ from spiralbevel gears in that the axis of the pinion is offset from the axis of the gear.
Fig.
S K Mondals
Chapter 3
Figure-Epicyclic gears
Mitres gear
Des
sign of Power
P
Trransmis
ssion Sy
ystem
S K Mo
ondals
C
Chapter
r3
Miter
M
gears are
a identical to bevel ge
ears except that in a miter
m
gear seet, both gearrs always have
th
he same num
mber of teetth. Their rattio, thereforre, is alway
ys 1 to 1. As a result, miter
m
gears are
no
ot used wheen an appliccation calls for
f a changee of speed.
When
n equal bevel gears (having eq
qual teeth) connect two shafts
s whose ax
xes
are mutually
m
pe
erpendicullar, then th
he bevel ge
ears are kn
nown as mitres.
m
Figure- Miter
M
gears
Minimum
M
m Num
mber off Teeth
h on th
he Pinio
on in Order
O
to
Avoid
A
In
nterfere
ence
Th
he number of teeth on the pinion (Tp) in orderr to avoid in
nterference may be obtained from the
fo
ollowing rela
ation:
Tp =
Where
W
2 Aw
11
n 2 1
G 1 + + 2 sin
G G
AW = Fra
action by wh
hich the stan
ndard adden
ndum for th
he wheel shoould be
Mu
ultiplied, (geenerally AW = 1)
G = Geear ratio or velocity rattio = TG / TP = DG / DP,
= Prressure angle or angle of obliquity.
Minim
mum numbe
er of teeth foor involute rack and piinion arrang
gement for pressure
p
an
ngle
of 20 is
Tmin =
2 AR
2 1
=
= 17.1
sin 2 sin 2 20o
aas > 17
So, Tmin = 18
The minimum
m
number
n
of teeth on tthe pinion to operate without in
nterference in
standa
ard full heig
ght involutee teeth gearr mechanism
m with 20 p
pressure ang
gle is 18.
In fulll depth 14
4
1
degree involute sy
ystem, the smallest
s
nu
umber of teeeth in a pin
nion
2
which
h meshes witth rack with
h out interfeerence is 32
2.
De
esign off Power Transm
mission S
System
S K Monda
M
als
Chapte
er 3
Forms
s of teeth
Cycloiidal tee
eth
A cycloid
d is the curv
ve traced by
y a point on
n the circum
mference off a circle wh
hich rolls without
w
slipping on
n a fixed sttraight line. When a cirrcle rolls wiithout slipp
ping on the outside of a fixed
circle, the curve trace
ed by a poin
nt on the cirrcumferencee of a circle is known as
a epicycloiid. On
the other hand, if a circle
c
rolls without
w
slip
pping on thee inside of a fixed circlle, then the curve
erence of a circle
c
is calleed hypocyc
cloid.
traced by a point on the circumfe
F
Fig.
cycloid
dal teeth of a gear
Advan
ntages of
o cyclo
oidal ge
ears
Following are the adv
vantages of cycloidal geears:
1. Since th
he cycloidall teeth have
e wider flan
nks, thereforre the cyclooidal gears are
a strongerr than
the involu
ute gears foor the same
e pitch. Duee to this reeason, the ccycloidal tee
eth are preeferred
especially for cast teeth.
2. In cyclo
oidal gears, the contact takes place between
n a convex flank and concave su
urface,
whereas in
n involute gears, the convex
c
surffaces are in
n contact. This
T
conditioon results in
i less
wear in cycloidal gea
ars as com
mpared to in
nvolute gea
ars. Howeveer the diffeerence in wear
w
is
negligible..
3. In cyclo
oidal gears, the interfference does not occur at all. T
Though therre are advan
ntages
of cycloida
al gears bu
ut they are outweighed by the greater
g
simp
plicity and flexibility of the
involute gears.
Involu
ute teeth
h
An involutte of a circlle is a plane
e curve gen
nerated by a point on a tangent, which
w
rolls oon the
circle with
hout slipping or by a po
oint on a tau
ut string wh
hich is unw
wrapped from
m a reel as sshown
in figure below.
b
In con
nnection witth toothed w
wheels, the circle is knoown as basee circle.
Des
sign of Power
P
Trransmis
ssion Sy
ystem
S K Mo
ondals
C
Chapter
r3
F
Fig.
Figure-inv
volute teeth
h
Advantages
A
s of involutte gears
Foollowing aree the advan
ntages of inv
volute gearss:
1.. The most important
i
advantage
a
o the involu
of
ute gears is that the centre distance for a pair of
in
nvolute gearrs can be va
aried within
n limits with
hout changing the veloccity ratio. This
T
is not true
fo
or cycloidal gears
g
which
h require exact centre d
distance to be
b maintain
ned.
2.. In involutee gears, the pressure an
ngle, from tthe start of the
t engagem
ment of teetth to the end
d of
th
he engagement, remain
ns constantt. It is necesssary for sm
mooth running and less wear of gea
ars.
But in cyclooidal gears, the pressu
ure angle iis maximum
m at the b
beginning of engagemeent,
re
educes to zeero at pitch
h point, starrts increasiing and aga
ain becomess maximum
m at the end
d of
en
ngagement. This resultts in less sm
mooth runnin
ng of gears.
De
esign off Power Transm
mission S
System
S K Monda
M
als
Chapte
er 3
Contact ratio
o
Note: Thee ratio of the length of arc of conta
act to the ciircular pitch
h is known as contact ratio
i.e. numbeer of pairs off teeth in coontact.
Contact ratio =
Pc (cos )
Fig.
The zone of
o action of meshing
m
gea
ar teeth is sshown in fig
gure above. We recall th
hat tooth
Contact be
egins and ends
e
at the intersections of the tw
wo addendu
um circles with
w
the preessure
line. In fig
gure above initial conttact occurs at a and fiinal contactt at b. Tootth profiles d
drawn
through th
hese points intersect th
he pitch circcle at A and
d B, respectiively. As shoown, the disstance
AP is calleed the arc of approac
ch (qa), and the distancce P B, the arc of rece
ess (qr ). Th
he sum
of these is the arc of action
a
(qt).
The ra
atio of the le
ength of arcc of contact to
t the circular pitch is known as contact
c
rattio i.e.
numbe
er of pairs of teeth in
n contact. T
The contact ratio for gears is greater
g
than
n one.
Conta
act ratio sh
hould be at
a least 1.2
25. For ma
aximum smooothness an
nd quietnesss, the
contactt ratio shou
uld be betwe
een 1.50 and
d 2.00. High
h-speed app
plications sh
hould be dessigned
with a face-contacct ratio of 2.00 or higher for best reesults.
Des
sign of Power
P
Trransmis
ssion Sy
ystem
S K Mo
ondals
C
Chapter
r3
In
nterfere
ence
The con
ntact of portions
p
of tooth profiles
p
that are no
ot conjuga
ate is called
interfference.
Contact begins
b
when
n the tip of the driven tooth conta
acts the flan
nk of the drriving tooth.. In
this case the flank off the driving
g tooth firstt makes con
ntact with th
he driven toooth at pointt A,
and this occurs
o
beforre the involu
ute portion oof the drivin
ng tooth com
mes within range.
r
In other
words, contact is occu
urring below
w the base circle of gea
ar 2 on the noninvolute
n
e portion of the
flank. The actual efffect is that the involutte tip or face of the driiven gear te
ends to dig out
the nonin
nvolute flank
k of the driv
ver.
F
Fig.
Interfference can be elimina
ated by usiing more te
eeth on thee pinion. However,
H
if the
pinion
n is to tran
nsmit a giv
ven amoun
nt of powerr, more teeeth can be used only by
increa
asing the pittch diameteer.
There
e are sever
ral ways to
o avoid interfering:
i. Increase num
mber of gear teeth
ii. Moodified invo
olutes
iii. Moodified addeendum
iv. Increased cen
ntre distance
e.
De
esign off Power Transm
mission S
System
S K Monda
M
als
Face Width
Chapte
er 3
Fig.
Beam Streng
gth of Gear
G
Tooth
The beam strength off gear teeth is determin
ned from an equation (k
known as Lewis
L
equa
ation)
and the load
l
carryin
ng ability of
o the tooth
hed gears as determiined by thiis equation gives
satisfactorry results. In
I the invesstigation, Leewis assumeed that as tthe load is being
b
transm
mitted
from one gear
g
to anotther, it is alll given and taken by on
ne tooth, because it is not
n always safe
s
to
S K Mondals
Chapter 3
assume that the load is distributed among several teeth, considering each tooth as a cantilever
beam.
Notes: (i) The Lewis equation am applied only to the weaker of the two wheels (i.e. pinion or
gear).
(ii) When both the pinion and the gear are made of the same material, then pinion is the
weaker.
(iii) When the pinion and the gear are made of different materials, then the product of
( w y ) or ( o y ) is the deciding factor. The Lewis equation is used to that wheel for which
( w y ) or ( o y ) is less.
WT h ) t / 2 (WT h) 6
(
=
=
b.t 3 / 12
b.t 2
Where
M = Maximum bending moment at the critical section BC = WT h,
WT = Tangential load acting at the tooth,
h = Length of the tooth,
y = Half the thickness of the tooth (t) at critical section BC = t/2,
I = Moment of inertia about the centre line of the tooth = b.t3/12,
b = Width of gear face.
Lewis form factor or tooth form factor
WT = w b pc y = w b m y
The quantity y is known as Lewis form factor or tooth form factor and WT (which is the
tangential load acting at the tooth) is called the beam strength of the tooth.
Lewis form factor or tooth form factor
S K Mondals
Chapter 3
0.684
,for 14 1 2 0 composite and full depth involute system.
T
0.912
= 0.154
,for 200 full depth involute system.
T
0.841
= 0.175
,for 200 stub system.
T
y = 0.124
Example: A spur gear transmits 10 kW at a pitch line velocity of 10 m/s; driving gear
has a diameter of 1.0 m. find the tangential force between the driver and
the follower, and the transmitted torque respectively.
Solution: Power transmitted = Force Velocity
10 103 = Force 10
10 103
= 1000 N / m
10
diameter
Torque Transmitted = Force
2
1
= 1000 = 1000 0.5
2
= 500N m = 0.5 kN m
Force =
Where, Q =
2 Tg
Tg + Tp
=
2 Tg
Tg Tp
2c sin cos 1
1
+
1.4
E
E
2
1
BHN
= 0.16
100
Gear Lubrication
All the major oil companies and lubrication specialty companies provide lubricants for gearing
and other applications to meet a very broad range of operating conditions. General gear
lubrication consists of high-quality machine oil when there are no temperature extremes or
other adverse ambient conditions. Many of the automotive greases and oils are suitable for a
broad range of gearing applications.
For adverse temperatures, environmental extremes, and high-pressure applications, consult
the lubrication specialty companies or the major oil companies to meet your particular
requirements or specifications.
Des
sign of Power
P
Trransmis
ssion Sy
ystem
S K Mo
ondals
C
Chapter
r3
Th
he following
g points refeer especially
y to spiral a
and hypoid bevel
b
gears:
(a
a) Both spiral and hypo
oid bevel geears have coombined rollling and sliding motio
on between the
teeeth, the rollling action being beneficial in ma
aintaining a film of oil between
b
thee tooth matting
su
urfaces.
(b
b) Due to th
he increased sliding veelocity betw
ween the hy
ypoid gear pair, a morre complica
ated
lu
ubrication sy
ystem may be
b necessarry.
Simple
S
G
Gear
trrain
A gear train is one or more
m
pairs of gears op
perating tog
gether to trransmit pow
wer. When ttwo
ge
ears are in mesh,
m
their pitch circlees roll on eacch other witthout slippa
age.
is pitch
h radius of gear
g
1; r2 iss pitch radiu
us of gear 2; 1 is angu
ular velocity
y of gear 1; and
a
2 is angularr velocity of gear 2 then
n the pitch liine velocity is given by
Iff
r1
V = r11 = r2 2
The velocity
v
ratio
o is
r
1
= 2
2
r1
F
FigureSimple gear tra
ain
Compou
C
und gea
ar train
n
S K Mondals
Chapter 3
N T T T
=
N T T T
F
Des
sign of Power
P
Trransmis
ssion Sy
ystem
S K Mo
ondals
C
Chapter
r3
d d
d d
+ =
+
2 2
2
2
2
Th
he diametriic pitch rela
ates the diam
meters and the numberrs of teeth, P = T/d. Rep
placing
All the diameeters give
T2 / ( 2P
2 ) + T3 / ( 2P ) = T4 / ( 2P
2 ) + T5 / ( 2P )
Assuming a constant
c
dia
ametral pitcch in both sttages, we ha
ave the geom
metry condiition
Sttated in term
ms of numb
bers of teeth
h:
T2 + T3 = T4 + T5
Th
his conditioon must be exactly
e
satissfied, in add
dition to the
e previous ra
atio equatio
ons, to
Prrovide for th
he in-line coondition on the input an
nd output shafts.
In
n the compoound gear train
t
shown
n in the figu
ure, gears A
an
nd C have equal num
mbers of teeth and gea
ars B and D
ha
ave equal nu
umbers of teeth.
F
From
the fiigure rA + rB = rC + rD or
o TA +TB = TC+TD and
ass NB+NC it must
m
be TB =T
= D & TA=T
TC
Or
[ where
NB
N
= D or NC =
NA
NC
NA ND
NB = Nc ]
Epicycli
E
ic gear train
De
esign off Power Transm
mission S
System
S K Monda
M
als
Chapte
er 3
Consider the
t following Epicyclic gear trai
narm =
nsun
100
00
=
= 200
0 rpm
5
( 80 / 20 ) + 1
The speed
d of the finall drive is 200 rpm clock
kwise. The reduction
r
ra
atio for the gearbox
g
is
Given by nsun/narm = 1000/200 = 5.
5 To determ
mine the spe
eed of the pllanets use
The planetts and sun are
a in mesh
h, so
n planet / n arm
n sum / n arm
n planet n arm
n sum n arm
NS
NP
NS
NP
n planet ( 200 )
20
30
1000 ( 200)
20
( 80
00 ) 200 = 333 rpm
n planet =
30
d of rotation of the plane
etary gears is 333 rpm counter-cloockwise.
The speed
e a table forr the epicyc
clic gear arrangemen
a
nt shown iin the figur
re below.
Now make
Des
sign of Power
P
Trransmis
ssion Sy
ystem
S K Mo
ondals
C
Chapter
r3
Arm
1.
+x
x
2.
x+y
3
--N 2
x
N3
y
N2
yx
N3
4
-N 2
x
N3
y
Formula
F
a List fo
or Gearrs:
(a
a) Spurr Gear
Name
N
Speed ratio
6:1 to 10:1
1
for h
high speed helical
h
For h
high speed spur.
2.. Bevel
3.. Worm
1:1 to 3:1
3
10:1 to 100:1 proviided 100 KW
K
SPUR
S
G
GEAR
(i) Circular pitch (p) =
d
T
(ii) Diametr
ral pitch (P
P) =
T
d
(iii) pP =
d 1
= or d = mT
m
T P
p
Tg
=
v) Speed ra
atio (G) =
(v
g
Tp
(iv) Module (m) =
1
( dg + d p )
2
(v
vi) centre-tto-centre distance
d
=
=
( ha ) = 1m
( hf ) =11.25 m
1
m Tg + Tp
2
vii) Addend
dum
(v
Clearanc
ce (C) = 0.2
25 m
5
-N 4 N 2
x
N5 N3
y
N4 N2
y
x
N5 N3
S K Mondals
(viii)
Pt =
Chapter 3
2T
d
Pr = Pt tan
PN =
Pt
cos
Tmin, pinion =
2 Aw
11
G 1 + + 2 sin 2 1
GG
G = Gear ratio =
zg
zp
ha
for pinion
m
h
= fraction of addendum to module = f for gear (generally 1)
m
Aw
b = mb b Y Lewis equation
Where b =
ult
3
0.912
2 Tg
Where Q =
Tg + Tp
=
2 Tg
Tg - Tp
2c sin cos 1
1
+
1.4
E1 E2
BHN
= 0.16
100
(xiv)
S K Mondals
Peff =
Cs
Pt
Cv
Chapter 3
where Cv =
=
=
(xv)
3
,
3+V
6
,
6+v
5.6
5.6 + v
en p Tp br1r2
2530 r12 + r22
S K Mondals
Chapter 3
= pcos
( 2) Pn
P
cos
(3) pP =
1
= mcos P =
m
( 4 ) mn
m = transverse module.
mn = normal module.
p
m
=
;
tan tan
tan n
( 6 ) cos =
tan
(5 ) pa
pa = axial pitch.
n = normal pressure angle ( usually 20 ) .
= transverse pressure angle.
Tmn
TP
= zm =
;
d = pitch circle diameter.
cos
mn
(8) a =
{T1 + T2 } centre to - centre distance.
2 cos
T
d
( 9 ) T = 3 ; d = 2
cos
cos
(7 ) d =
(10) An imaginary spur gear is considered with a pitch circle diameter of d and module m n is
called formative or virtual spur gear.
(11) Helix angle varies from 15 to 25.
(12) Preference value of normal modus ( mn ) = 1, 1.25, 1.5, 2, 3, 4, 5, 6, 8
(13) Addendum ( ha ) = mn ; dedendum ( h f ) = 1.25 mn , clearence = 0.25mn
(14)
60 x106 x ( KW )
2Mt
= Pcosn cos ; Mt =
N - mm
d
2N
tann
Pr = Pt
= Psinn
cos
Pt =
bQd pK
cos2
(17)
S K Mondals
Peff =
Chapter 3
en p Tp br1r2
Cs Pt
5.6
; Cv =
; Pd =
Cv
5.6 + v
2530 r12 + r22
(iii) Axial pitch ( px ) = distance between two consecutive teeth-measured along the axis of the
worm.
(iv) The lead (l) = when the worm is rotated one revolution, a distance that a point on the
helical profile will move.
(v)
l = px T1 ;
d z = mT2
(vi) Axial pitch of the worm = circular pitch of the worm wheel
d 2
Px =
= m
[ICS - 04]
T2
l = Px T1 = mT1
l
T
(vii) Lead angle ( ) = tan-1 1 = tan-1
q
d1
(viii) centre-to-centre distance (a) =
1
1
( d1 + d2 ) = m ( T1 + T2 )
2
2
( )
dedendum ( h ) = ( 2.2 cos -1 ) m
h a2 = m ( 2 cos -1 )
c = 0.2 m cos
addendum h a1 = m
f1
(xii) F = 2m
h f2 = m (1 + 0.2 cos )
(xiii)
F
F
= sin-1
; l r = d a1 + 2C sin-1
= length of the root of the worm wheel teeth
d a + 2C
d a + 2C
1
S K Mondals
(xiv) ( P1 )t =
Chapter 3
2mt
coscos - sin
sin
; ( P1 )a = ( P1 )t
; ( P1 )r = ( P1 )t
d1
cossin + cos
cos sin + cos
(xv) Efficiency () =
Power output
cos - tan
=
Power input
cos + tan
d1n1
m / s (remaining 4 cheak)
60000 cos
K ( t - t0 ) A
1000 (1 - )
S K Mondals
Chapter 3
Spur gear
GATE-1.
Type of gear
P Helical
Q Spiral
R Hypoid
S Rack and pinion
(a) P-2, Q- 4, R- 1, S- 6
(b) P-1, Q- 4, R- 5, S- 6
GATE-1Ans. (a)
GATE-2.
[GATE-2008]
Description
1. Axes non parallel and intersecting
2. Axes parallel and teeth are inclined to the
axis
3. Axes parallel and teeth are parallel to the
axis
4. Axes are perpendicular and intersecting,
and teeth are inclined to the axis
5. Axes are perpendicular and used for large
speed reduction
6. Axes parallel and one of the gears has
infinite radius
(c) P-2, Q- 6, R- 4, S- 2
(d) P-6, Q- 3, R- 1, S- 5
One tooth of a gear having 4 module and 32 teeth is shown in the figure.
Assume that the gear tooth and the corresponding tooth space make equal
intercepts on the pitch circumference. The dimensions 'a' and 'b',
respectively, are closest to
[GATE-2008]
Classification of Gears
GATE-3.
[GATE-2004]
Arrangement of shafts
1. Non-parallel off-set shafts
2. Non-parallel intersecting shafts
3. Non-parallel non-intersecting shafts
4. Parallel shafts
(b) P-2 Q-3 R-4 S-1
S K Mondals
Chapter 3
Pitch point
In spur gears, the circle on which the involute is generated is called the
[GATE-1996]
(a) Pitch circle
(b) clearance circle
(c) Base circle
(d) addendum circle
GATE-4Ans. (a)
GATE-4.
Interference
Tooth interference in an external in volute spur gear pair can be reduced
by
[GATE-2010]
(a) Decreasing center distance between gear pair
(b) Decreasing module
(c) Decreasing pressure angle
(d) Increasing number of gear teeth
GATE-6Ans. (d)
GATE-6
S K Mondals
Chapter 3
Twenty degree full depth involute profiled 19-tooth pinion and 37-tooth
gear are in mesh. If the module is 5 mm, the centre distance between the
gear pair will be
[GATE-2006]
(a) 140 mm
(b) 150 mm
(c) 280 mm
(d) 300 mm
GATE-8Ans. (a)
D + D2 mT1 + mT2 5 (19 + 37 )
Centre dis tan ce = 1
=
=
= 140mm
2
2
2
GATE-8.
(a) 3552
GATE-10Ans. (a)
(b) 261 1
(c) 1776
[GATE -2009]
(d) 1305
GATE-11. Given that the tooth geometry factor is 0.32 and the combined effect of
dynamic load and allied factors intensifying the stress is 1.5; the minimum
allowable stress (in MPa) for the gear material is
[GATE -2009]
(a) 242.0
(b) 166.5
(c) 121.0
(d) 74.0
GATE-11Ans. (b)
(a) 140
GATE-12Ans. (b)
(b) 150
(c) 160
[GATE-2007]
(d) 170.
(a) 1.21
GATE-13Ans. (c)
(b) 1.25
(c) 1.29
[GATE-2007]
(d) 1.33
(a) 77.23
(b) 212.20
(c) 225.80
[GATE-2007]
(d) 289.43
S K Mondals
Chapter 3
GATE-14Ans. (c)
GATE-15. If the drive efficiency is 80%, then torque required on the input shaft to
2F = 1000, or F = 500 N
Let T1 be the torque applied by motor.
T2 be the torque applied by gear.
Power transmission = 80%
2T2 1
Now, T11 =
0.8
2 F (D / 2) 1
or
T1 =
0.8
2
(c) 32 Nm
[GATE-2004]
(d) 50 Nm
0.16 1 1
2
0.8 4
= 25 N m.
= 2 500
GATE-16. If the pressure angle of the rack is 20, then force acting along the line of
P cos = F
Force acting along the line of action,
[GATE-2004]
(d) 600 N
S K Mondals
Chapter 3
F
cos
500
=
cos 20
= 532N
P=
(a) 64 and 45
(b) 45 and 64
GATE-17Ans. (a)
N
N
D
Given, 1 = 12, 1 = 4 = 2
N2
N2
D1
(c) 48 and 60
[GATE-2003]
(d) 60 and 48
m1 = 3, m2 = 4
Now,
D1 D2
=
Z1 Z2
Z1 D1 N 2 1
=
=
=
Z2 D2 N1 4
Z2 = Z1 4 = 64
12 =
D4
=3
D3
Also,
Z3 D3
=
Z4 D4
Z 4 = Z3
D4
D3
D4
= Z3 3 = 15 3
D3
= 45
GATE-18. The centre distance in the second stage is
(a) 90 mm
GATE-18Ans. (b)
(b) 120 mm
(c) 160 mm
[GATE-2003]
(d) 240mm
S K Mondals
Chapter 3
D4 + D3
2
Now,
x = r4 + r3 =
But
D4 D3
=
=4
Z4 Z3
D4 = 180, D3 = 60
x=
180 + 60
= 120mm
2
clockwise (CW) and arm = 80 rad/s counter clockwise (CCW). The angular
velocity 5 , (in rad/s) is
(a) 0
GATE-19Ans. (c)
[GATE-2010]
(b) 70 CW
Arm
1.
+x
2.
x+y
3
N 2
x
N3
y
y
N2
x
N3
4
N 2
x
N3
y
(d) 140 CW
5
N 4 N 2
x
N5 N3
y
y
x + y = 100 (cw)
y = 80 (ccw)
Speed of Gear ( W5 ) = 80
32 20
180 = 140
80 24
= 140 (ccw)
N4 N2
x
N5 N3
Des
sign of Power
P
Trransmis
ssion Sy
ystem
S K Mo
ondals
C
Chapter
r3
GA
ATE-20. An
n epicycliic gear tr
rain is sh
hown
schematically in the ad
djacent fig
gure.
Th
he sun gea
ar 2 on the
e input sha
aft is
a 20 teeth external ge
ear. The pllanet
ge
ear 3 is a 40 teeth external g
gear.
Th
he ring gear
g
5 is a 100 tteeth
internal gea
ar. The ring
r
gear 5 is
fix
xed and th
he gear 2 is
s rotating at 60
rp
pm (ccw = counter--clockwise and
cw
w = clockwise).
Th
he arm 4 attached to the ou
utput
sh
haft will rotate at
(a)) 10 rpm ccw
w
(b)) 10 rpm ccw
w
(c)) 12 rpm cw
w
(d)) 12 rpm ccw
w
[GATE -2
2009]
GA
ATE-20Ans
s. (a)
GA
ATE-21 Th
he arm OA
A of an ep
picyclic gea
ar train sh
hown in fiigure revo
olves coun
nter
clo
ockwise ab
bout O wiith an ang
gular veloc
city of 4 ra
ad/s. Both gears are
e of
sa
ame size. Tire
T
angullar velocity of gear C, if the ssun gear B is fixed,, is
[GATE-1995]
(a)) 4 rad / secc
Expla
anation
Fix arm
a
A
Give one rotation to B
Multtiply by x
Add y
B is
i fixed, theerefore
An
ngular veloccity of gear
Arm A
0
0
y
1
+x
X+ y
-1
-x
y-x
x+y = 0
y = rad/sec( ccw )
x = -4 rad//sec(cw)
C = y x = 4 (-4) = 8 rad/s
S K Mondals
Chapter 3
Arm
+1
0
Sun
+1
Planet
+1
80 30
30 20
80
30
Ring
+1
1
5
3
100
= 20
5
GATE-23. Two mating spur gears have 40 and 120 teeth respectively. The pinion
We know
N P TG
=
N G TP
1200 120
=
NG
40
or
N G = 400 r.p.m
Des
sign of Power
P
Trransmis
ssion Sy
ystem
S K Mo
ondals
C
Chapter
r3
A planetary
y gear tra
ain has fou
ur gears a
and one ca
arrier. Angular velo
ocities of the
t
ge
ears are 1, 2, 3, an
nd 4 respe
ectively. Th
he carrier rotates wiith angular
r velocity 5,
GA
ATE-24. Wh
hat is the relation
r
be
etween the
e angular velocities
v
o
of Gear 1 and
a
Gear 4?
[GATE-200
06]
GA
ATE-24Ans
s. (a)
1 5
=3
2 5
3 5
=2
4 5
(with
h respect to ccarrier5)
Ass,3 2
1 5
=6
4 5
GA
ATE-25. Fo
or (1 = 60
0 rpm cloc
ckwise (cw
w) when lo
ooked from
m the left,, what is the
t
an
ngular velo
ocity of th
he carrier and its dir
rection so that Gear
r 4 rotatess in
co
ounter cloc
ckwise (ccw) direction at twic
ce the angu
ular veloc
city of Gea
ar 1
wh
hen looked
d from the left?
[GATE-200
06]
(a)) 130 rpm, cw
c
(b) 223 rpm,
r
ccw
(c)) 256 rpm, cw
(d) 156 rpm,
r
ccw
GA
ATE-25Ans
s. (d)
1 = 60 rpm (C
Clockwise)
4 =120 rpm (C
Counter clocck wise)
60 5
=6
120 5
5 = 156 i.ee.counter cloockwise
Worm
W
G
Gears
GA
ATE-26. La
arge speed
d reduction
ns (greater
r than 20) in one sta
age of a ge
ear train are
a
po
ossible thro
ough
(a)) Spur geariing
(b) Worm
W
gearin
ng
GA
ATE-26Ans
s. (b)
[GATE-2002]
(d) Helical
H
geariing
GA
ATE-27. A 1.5 kW mo
otor is runn
ning at 144
40 rev/min. It is to be
e connecte
ed to a stirrer
ru
unning at 36 rev /min.
/
The gearing arrangem
ment suita
able for this
ap
pplication is
[GATE-2000]
S K Mondals
Chapter 3
[GATE-1997]
The velocity ratio between pinion and gear in a gear drive is 2.3, the
module of teeth is 2.0 mm and sum of number of teeth on pinion and gear
is 99. What is the centre distance between pinion and the gear? [IES 2007]
(a) 49.5 mm
(b) 99 mm
(c) 148.5 mm
(d) 198 mm
D1 + D2
mT1 + mT2
m
2
=
=
(T1+ T2) =
99 = 99mm
2
2
2
2
IES-2.
The working surface above the pitch surface of the gear tooth is termed as
[IES-1998]
(a) Addendum
(b) dedendum
(c) flank
(d) face
IES-3. Ans. (d)
o
IES-4.
1
composite system gears
2
List II
2
pd
0.157
2.
pd
1.157
3.
pd
1.
[IES-1992]
S K Mondals
Chapter 3
D. Addendum
Code:
(a)
(c)
IES-4. Ans. (c)
A
1
3
4.
B
2
2
C
3
1
D
4
4
1
pd
(b)
(d)
A
4
3
B
3
1
C
2
2
D
1
4
IES-5. Match List I with List II and select the correct answer using the codes given
below the lists:
[IES-1993]
List I (Standard tooth/arms)
List II (Advantages or disadvantages)
A. 20 and 25 systems
1. Results in lower loads on bearing
B. 14.5o stub-tooth system
2. Broadest at the base and strongest in
bending
C. 25 Full depth system
3. Obsolete
D. 20 Full depth system
4. Standards for new applications
Code:
A
B
C
D
A
B
C
D
(a)
4
3
2
1
(b)
3
1
2
4
(c)
3
2
1
4
(d)
4
2
3
1
IES-5. Ans. (a)
Assertion (A): When one body drives another by direct contact, their contact
points must have equal components of velocity normal to the surfaces at the point of
contact.
Reason (R): Two points in the same body must have the same component of
velocity relative to the third body, in the direction of the line joining the two points.
[IES-1993]
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-6Ans. (a)
IES-6.
Classification of Gears
IES-7.
[IES-1996]
D
4
1
Match List-l (Type of Gears) with List-II (Characteristics) and select the
correct answer using the code given below the Lists:
[IES-2006]
List-I
List -II
A. Helical gearing
1. Zero axial thrust
B. Herringbone gearing
2. Non-inter-changeable
C. Worm gearing
3. Skew shafts
D. Hypoid gearing
4. Parallel shafts
S K Mondals
A
(a) 4
(c) 4
IES-8Ans. (a)
B
1
2
Chapter 3
C
3
3
D
2
1
(b)
(d)
A
3
3
B
2
1
C
4
4
D
1
2
IES-9.
Match List I with List II and select the correct answer using the code given
below the Lists:
[IES 2007]
List I
List II
A. Worm gear
1. Imposes no thrust load on the shaft
B. Spur gear
2. To transmit power between two nonintersecting
shafts which are perpendicular to
each
other
C. Herringbone gear
3. To transmit power when the shafts are
parallel
D. Spring level gear
4. To transmit power when the shafts are at
right
angles to one another
Code: A
B
C
D
A
B
C
D
(a)
1
2
3
4
(b)
2
3
1
4
(c)
1
2
4
3
(d)
2
3
4
1
IES-9Ans. (b)
IES-10.
Match List I (Type of Gear/Gear Train) with List II (Different Usage and
Drive) and select the correct answer using the code given below the Lists:
List I
List II
[IES-2005]
A Epicyclic gear train
1. Reduces end thrust
B. Bevel Gear
2. Low gear ratio
C. Worm-worm Gear
3. Drives non-parallel nonintersecting shafts
D. Herringbone Gear
4. Drives non-parallel intersecting shafts
5. High gear ratio
A
B
C
D
A
B
C
D
(a) 5
4
3
1
(b)
2
3
4
5
(c) 5
3
4
1
(d)
2
4
3
5
IES-10Ans. (a)
IES-11.
[IES-2004]
IES-12.
When two shafts are neither parallel nor intersecting, power can be
transmitted by using
[IES-1998]
(a) A pair of spur gears
(b) a pair of helical gears
(c) An Oldham's coupling
(d) a pair of spiral gears
IES-13Ans. (d)
S K Mondals
Chapter 3
IES-14.
Mitres gear
IES-16.
Mitre gears
[IES-1992]
(a) spur-gears with gear ratio 1: 1
(b) Skew gears connecting non-parallel and nonintersecting shafts
(c) Bevel gears transmitting power at more than or less than 90
(d) Bevel gears in which the angle between the axes is 90 and the speed ratio of
the gears is 1: 1
IES-16Ans. (d)
IES-17.
Match List-I (Gears) with List-II (Configurations) and select the correct
answer using the codes given below the Lists:
[IES-2003]
List-I
List-II
(Gears)
(Configurations)
A Spur
1. Connecting two non-parallel or intersecting but coplanar
shafts
B. Bevel
2. Connecting two parallel and coplanar shafts with teeth
parallel to the axis of the gear wheel
C. Helical
3. Connecting two parallel and coplanar shafts with teeth
inclined to the axis of the gear wheel
D. Mitre
4. Connecting two shafts whose axes are mutually
perpendicular to each other
Codes:
A
B
C
D
A
B
C
D
(a)
2
4
3
1
(b)
3
1
2
4
(c)
2
1
3
4
(d)
3
4
2
1
IES-17Ans. (c)
Pitch point
IES-18.
When two spur gears having involute profiles on, their teeth engage, the
line of action is tangential to the
[IES-2003]
S K Mondals
(a) Pitch circles
(c) Addendum circles
IES-19Ans. (d)
Chapter 3
(b) Dedendum circles
(d) Base circles
Pressure angle
IES-20.
What is the value of pressure angle generally used for involute gears?
[IES-2006]
(a) 35
(b) 30
(c) 25
(d) 20
IES-20Ans. (d)
IES-21.
IES-23.
Assertion (A): An involute rack with 20 pressure angle meshes with a pinion of
14.5 pressure angle.
[IES-2002]
Reason (R): Such a matching is impossible.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-23Ans. (d)
IES-24.
Compared to gears with 200 pressure angle involute full depth teeth, those
with 200 pressure angle and stub teeth have
[IES 2007]
1. Smaller addendum.
2. Smaller dedendum.
3. Smaller tooth thickness.
4. Greater bending strength.
Which of the statements given above are correct?
(a) 1, 2 and 3
(b) 1, 2 and 4
(c) 1, 3 and 4
(d) 2, 3 and 4
IES-24Ans. (b)
IES-25.
[IES-1999]
S K Mondals
Chapter 3
o
A pinion of 14
1
pressure angle and 48 involute teeth has a pitch circle
2
2. Circular pitch of 18 mm
3. Addendum of 6 mm
4. Diametral pitch of
d 288
IES-25Ans. (b) Module = =
=6mm
T 48
d
Circular pitch =
= 6 = 18.84 mm
T
T
1
diametral pitch = =
d
6
11
113
(d) 2 and 4
; addendum = 1 module = 6 mm
IES-26.
S K Mondals
Chapter 3
IES-30.
IES-31.
1
In full depth 14
degree involute system, the smallest number of teeth in
2
[IES-1992]
IES-33.
Match List I with List II and select the correct answer using the codes
given below the lists:
List I (Terminology)
List II (Relevant terms)
[IES-1995]
A. Interference
1. Arc of approach, arc of recess, circular pitch
B. Dynamic load on tooth
2. Lewis equation
C. Static load
3. Minimum number of teeth on pinion
D. Contract ratio
4. Inaccuracies in tooth profile
Codes:
A
B
C
D
A
B
C
D
(a)
3
4
1
2
(b)
1
2
3
4
(c)
4
3
2
1
(d)
3
4
2
1
IES-33Ans. (d)
IES-34
Assertion (A): When a pair of spur gears of the same material is in mesh, the
design is based on pinion.
[IES-2002; 1993]
Reason (R): For a pair of gears of the same material in mesh, the 'strength factor'
of the pinion is less than that of the gear.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-34Ans. (a)
Cycloidal teeth
IES-35.
S K Mondals
Chapter 3
A thin circular disc is rolling with a uniform linear speed, along a straight
path on a plane surface.
[IES-1994]
Consider the following statements in this regard:
1. All points on the disc have the same velocity.
2. The centre of the disc has zero acceleration.
3. The centre of the disc has centrifugal acceleration.
4. The point on the disc making contact with the plane surface has zero
acceleration of these statements
(a) 1 and 4 are correct
(b) 3 and 4 are correct
(c) 3 alone is correct
(d) 2 alone is correct.
IES-37.Ans. (d)
Involute teeth
IES-38.
[IES-1997]
IES-39.
S K Mondals
Chapter 3
Contact ratio
IES-42.
Interference
IES-44.
An involute pinion and gear are in mesh. If both have the same size of
addendum, then there will be an interference between the
[IES-1996]
(a) Tip of the gear tooth and flank of pinion.
(b) Tip of the pinion and flank of gear.
(c) Flanks of both gear and pinion.
(d) Tips of both gear and pinion.
IES-46Ans. (a)
IES-47.
S K Mondals
Chapter 3
Match List-I with List-II and select the correct answer using the codes
given below the lists:
[IES-2001]
List-I
List-II
A. Undercutting
1. Beam strength
B. Addendum
2. Interference
C. Lewis equation
3. Large speed reduction
D. Worm and wheel
4. Intersecting axes
5. Module
Codes:
A
B
C
D
A
B
C
D
(a)
2
5
1
3
(b)
1
5
4
3
(c)
1
3
4
5
(d)
2
3
1
5
IES-49Ans. (a)
IES-50.
[IES-1999]
IES-51.
The motion transmitted between the teeth of two spur gears in mesh is
generally
[IES-1999]
(a) Sliding
(b) rolling
(c) Rotary
(d) party sliding and partly rolling
IES-52Ans. (b)
S K Mondals
Chapter 3
Assertion (A): The Lewis equation for design of gear tooth predicts the static load
capacity of a cantilever beam of uniform strength.
Reason (R): According to law of gears interchangeability is possible only when
gears have same pressure angle and same module. [IES-2008]
(a) Both A and R are true and R is the correct explanation of A
(b) Both A and R are true but R is NOT the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-55Ans. (b) The beam strength of gear teeth is determined from an equation (known as
Lewis equation) and the load carrying ability of the toothed gears as determined by
this equation gives satisfactory results. In the investigation, Lewis assumed that as
the load is being transmitted from one gear to another, it is all given and taken by
one tooth, because it is not always safe to assume that the load is distributed among
several teeth.
Notes: (i) The Lewis equation is applied only to the weaker of the two wheels (i.e. pinion or
gear).
(ii) When both the pinion and the gear are made of the same material, then pinion is
the weaker.
(iii) When the pinion and the gear are made of different materials, then the product of
( w y ) or ( o y ) is the deciding factor. The Lewis equation is used to that wheel
for which ( w y ) or ( o y ) is less.
IES-56.
Assertion (A): The Lewis equation for gear tooth with involute profile predicts the
static load capacity of cantilever beam of uniform strength.
[IES-1994]
S K Mondals
Chapter 3
Reason (R): For a pair of meshing gears with involute tooth profile, the pressure
angle and module must be the same to satisfy the condition of inter-changeability.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-57Ans. (c) For a pair of meshing gears with involute tooth profile, the pressure angle and
module must be the same to satisfy the condition of inter-changeability it is not
correct. Due to law of gearing.
IES-58.
Assertion (A): If the helix angle of a helical gear is increased, the load carrying
capacity of the tooth increases.
[IES-1996]
Reason (R): The form factor of a helical gear increases with the increasing in the
helix angle.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-61Ans. (a)
IES-62.
Match List I with List II and select the correct answer using the codes
given below the Lists:
List I
List II
[IES-2000]
A. Unwin's formula
1. Bearings
B. Wahl factor
2. Rivets
C. Reynoldss equation
3. Gears
D. Lewis form factor
4. Springs
Code:
A
B
C
D
A
B
C
D
(a)
1
4
2
3
(b)
2
3
1
4
(c)
1
3
2
4
(d)
2
4
1
3
IES-62Ans. (d)
IES-62.
S K Mondals
Chapter 3
10 103 = Force 10
10 103
= 1000 N / m
10
diameter
Torque Transmitted = Force
2
1
= 1000 = 1000 0.5
2
= 500 N m = 0.5 kN m
Force =
( a ) ( E p + Eg )
E p + Eg
E p Eg
( b )
( c ) 1 +
Ep
Eg
( d ) 1 +
Eg
E p
IES-63Ans. (b)
Gear Lubrication
IES-64.
Match List I (Types of gear failure) with List II (Reasons) and select the
correct answer using the codes given below the Lists
[IES-2004]
List I
List II
A. Scoring
1. Oil film breakage
B. Pitting
2. Yielding of surface under heavy loads
C. Scuffing
3. Cyclic loads causing high surface stress
D. Plastic flow
4. Insufficient lubrication
A
B
C
D
A
B
C
D
(a) 2
1
3
4
(b)
2
3
4
1
(c) 4
3
1
2
(d)
4
1
3
2
IES-64Ans. (b)
In a simple gear train, if the number of idler gears is odd, then the
direction or motion of driven gear will
[IES-2001]
(a) Be same as that of the driving gear
(b) Be opposite to that of the driving gear
(c) Depend upon the number of teeth on the driving gear
(d) Depend upon the total number of teeth on all gears of the train
IES-65Ans. (a)
IES-66.
[IES-1995]
S K Mondals
IES-67.
Chapter 3
IES-67Ans. (b)
mT2 + mT1
= 35
2
or T2 = 10
N1 = N i
T2
= N3
T1
N 3 T3
T T
10 10
= +N i 2 3 or 100 = 2400
or T4 = 40
T4
T1 T4
60 T4
mT3 + mT4
70
= 35 or m =
= 1.4
2
( 40 + 10 )
N4 =
IES-68
In a machine tool gear box, the smallest and largest spindles are 100 rpm
and 1120 rpm respectively. If there are 8 speeds in all, the fourth speed
will be
[IES-2002]
(a) 400 rpm
(b) 280 rpm
(c) 800 rpm
(d) 535 rpm
IES-68Ans. (b)
IES-69.
A fixed gear having 200 teeth is in mesh with another gear having 50 teeth.
The two gears are connected by an arm. The number of turns made by the
smaller gear for one revolution of arm about the centre of the bigger gear
is
[IES-1996]
(a)
2
4
(b) 3
(c) 4
(d) 5
The velocity ratio in the case of the compound train of wheels is equal to
[IES-2000]
IES-70Ans. (d)
S K Mondals
IES-71.
Chapter 3
Gear
:A B C D E
No of teeth:20 50 25 75 26 65
[IES-1999]
Gears BC and DE are moulded on parallel shaft rotating together. If the
speed of A is 975 r.p.m., the speed of F will be
IES-71Ans. (b)
Speed ratio
IES-72.
N F TA TC TE 20 25 26 4
=
=
=
N A TB TD TF 50 75 65 75
or N F = 975
4
= 52 rpm
75
(b) 2
1
2
1
(d)
8
(c)
[IES-1996]
IES-72Ans. (a)
Elements of higher pair like follower in cam
is under the action of gravity or spring force .
speed of lost driven or follower
Train value =
speed of the first gear
Train value =
S K Mondals
IES-73.
Chapter 3
[IES 2007]
IES-73Ans. (b)
From the figure rA+ rB = rC +rD or TA +TB =TC+TD and as NB+NC it must be
TB =TD & TA=TC
Or
NB ND
=
or NC =
N A NC
N A ND =
A reverted gear train is one in which the output shaft and input shaft
(a) Rotate in opposite directions
(b) are co-axial
[IES-1997]
(c) Are at right angles to each other
(d) are at an angle to each other
IES-75Ans. (b)
IES-76.
(a) 23
IES-76Ans. (a)
(b) 35
(c) 50
(d) 53
Two shafts A and B, in the same straight line are geared together through
an intermediate parallel shaft. The parameters relating to the gears and
pinions are given in the table:
[IES-2003]
S K Mondals
Chapter 3
Item
Driving wheel A
Driven wheel B
Driven wheel C on the intermediate shaft
Driving wheel D on the intermediate shaft,
in mesh with B
N A TC TB
=
N B TA TD
(c) DA + DC = DB + DD
Speed
NA
NB
NC
ND
Teeth
TA
TB
TC
TD
PCD
DA
DB
DC
DD
Module
m
m
m
m
N A TA TD
=
N B TC TB
(d) TA + TC = TB + TD
(b)
(a)
IES-77Ans. (b)
(i) D A + DC = D B + DD
(ii) mTA + mTC = mTB + mTD
(iii)
N A N A N C TC TB
=
=
N B N C N B TA N D
IES-78.
A gear having 100 teeth is fixed and another gear having 25 teeth revolves
around it, centre lines of both the gears being jointed by an arm. How
many revolutions will be made by the gear of 25 teeth for one revolution of
arm?
[IES-2009]
(a) 3
(b) 4
(c) 5
(d) 6
IES-78Ans. (c)
Arm
NA
NB
100
25
Multiplying through out by x
100
+x
0
x
25
y
y+x
y 4x
0
+1
Given that y + x = 0 x = -y = -1
( y = 1)
N B = y 4x = 5
If the annular wheel of an epicyclic gear train has 100 teeth and the planet
wheel has 20 teeth, the number of teeth on the sun wheel is
[IES-2003]
(a) 80
(b) 60
(c) 40
(d) 20
Des
sign of Power
P
Trransmis
ssion Sy
ystem
S K Mo
ondals
C
Chapter
r3
IE
ES-79Ans. (b)
( From geeometry
2d p + d s = d A
orr 2Tp + Ts = TA
orr Ts = TA 2Tp = 100 2 20 = 60
IE
ES-80.
In the epicy
yclic gear train sho
own in the
e given
fig
gure, A is fixed. A has
h
100 tee
eth and B has 20
teeth. If the
e arm C ma
akes three
e revolutio
ons, the
nu
umber of re
evolutionss made by B will be
(a)) 12
(b)) 15
(c)) 18
(d)) 24
[IES-199
97]
ES-80Ans. (c)
( For 1 revolution of C,
IE
NB = 1+
TA
100
= 1+
=6
TB
20
for 3revoolution, N D = 6 3 = 18
IE
ES-81.
An
n epicyclic
c gear train
n has 3 sha
afts A, B an
nd C, A is an input shaft
s
runniing
at 100 rpm clockwise.
c
B is an output shafft running
g at 250 rp
pm clockwiise.
To
orque on A is 50 kNm
m (clockwise). C is a fixed sha
aft. The torque to fix
xC
(a)) Is 20 kNm
m anticlockw
wise
[IES-200
02]
(b)) is 30 kNm anticlockw
wise
(c)) Is 30 kNm clockwise
(d)) Cannot be determined
d as the datta is insufficcient
IE
ES-81Ans. (b)
(
Now
1 M1 2 M2 = 0
M2 =
an
nd
100 50
0
= 20
250
KNm(antiiclockwise)
M1 + M2 + M3 = 0
50 20 + M3 = 0
kNm(clockw
wise)
M3 = 30k
m(anticlockw
wise)
= 30kNm
S K Mondals
IES-82.
Chapter 3
(a) 20 rpm
(c) 19
(b) 27
7
rpm
11
3
rpm
11
IES-82Ans. (c)
If = helix angle, and pc = circular pitch; then which one of the following
correctly expresses the axial pitch of a helical gear?
[IES 2007]
(a) pc cos
(b)
IES-83Ans. (c)
pc
cos
(c)
pc
tan
(d) pc sin
IES-84A helical gear has the active face width equal to b, pitch p and helix angle .
What should be the minimum value of b in order that contact IS
maintained across the entire active face of the gear?
[IES-2004]
(a) p cos
IES-84Ans. (d)
(b) p sec
b
(c) p tan
(d) p cot
P
tan
Assertion (A): Helical gears are used for transmitting motion and power between
intersecting shafts, whereas straight bevel gears arc used for transmitting motion
and power between two shafts intersecting each other at 90o. [IES-2000]
Reason (R): In helical gears teeth are inclined to axis of the shaft and arc in the
form or a helix.
Where as in bevel gears, teeth arc tapered both in thickness and height form one
end to the other.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-85Ans. (d)
IES-85.
Assertion (A): Shafts supporting helical gears must have only deep groove ballbearings.
[IES-1999]
Reason (R): Helical gears produce axial thrusts.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-86Ans. (a)
IES-86.
S K Mondals
Chapter 3
Assertion (A): Crossed helical gears for skew shafts are not used to transmit heavy
loads.
[IES-1995]
Reason (R) The gears have a point contact, and hence are not considered strong.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-87Ans. (b)
IES-87.
Bevel Gears
IES-88.
Worm Gears
Assertion (A): Tapered roller bearings must be used in heavy duty worm gear
speed reducers.
[IES-2005]
Reason (R): Tapered roller bearings are suitable for large radial as well as axial
loads.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-89Ans. (a)
IES-89.
IES-90.
For a speed ratio of 100 smallest gear box is obtained by using which of the
following?
[IES-2008]
(a) A pair of spur gears
(b) A pair of bevel and a pair of spur gears in compound gear train
(c) A pair of helical and a pair of spur gears in compound gear train
(d) A pair of helical and a pair of worm gears in compound gear train
IES-91.Ans. (d)
IES-92.
S K Mondals
Chapter 3
z w .m
dW
IES-93.
The lead angle of a worm is 22.5 deg. Its helix angle will be
[IES-1994]
(a) 22. 5 deg.
(b) 45 deg.
(c) 67.5 deg.
(d) 90C.
IES-93Ans. (c) = Pressure angle lead angle; + = 90; = helix angle = 90 - 22.5 =
67.5
Spur gear
IAS-1.
Match List I (Terms) with List II (Definition) and select the correct answer
using the codes given below the lists:
[IAS-2001]
List I
List II
A. Module
1. Radial distance of a tooth from the pitch circle to the
top of the tooth
B. Addendum
2. Radial distance of a tooth from the pitch circle to the
bottom of the tooth
C. Circular pitch
3. Distance on the circumference of the pitch circle from a
point of one tooth to the corresponding point on the next
tooth
4. Ratio of a pitch circle diameter in mm to the number of
teeth
Codes:
A
B
C
A
B
C
(a)
4
1
3
(b)
4
2
3
(c)
3
1
2
(d)
3
2
4
IAS-1Ans. (a)
IAS-2
14
Module
14
[IAS-2001]
D
60
14 1
1
S K Mondals
Chapter 3
Material
Steel
Brass
Brass
Steel
Which of these gears form the pair of spur gears to achieve a gear ratio of
3?
(a) A and B
(b) A and D
(c) B and C
(d) C and D
IAS-2Ans. (b)
For a gear pair i) module must be same
(ii) Pressure angle must be same.
IAS-3.
If the number of teeth on the wheel rotating at 300 r.p.m. is 90, then the
number of teeth on the mating pinion rotating at 1500 r.p. m. is[IAS-2000]
(a) 15
(b) 18
(c) 20
(d) 60
IAS-3Ans. (b)
Peripheral velocity (DN) = constant. D1 N1 = D 2 N 2 and D = mT
N1
300
= 90
= 18
1500
N2
N
T
Or you may say speed ratio, 1 = 2
N 2 T1
or mT1 N1 = mT1 N1 or T2 = T1
IAS-4.
A rack is a gear of
(a) Infinite diameter
(c) zero pressure angle
IAS-4Ans. (a)
[IAS-1998]
(b) infinite module
(d) large pitch
Classification of Gears
IAS-5.
Assertion (A): While transmitting power between two parallel shafts, the noise
generated by a pair of helical gears is less than that of an equivalent pair of spur
gears.
[IAS-2000]
Reason(R): A pair of helical gears has fewer teeth in contact as compared to an
equivalent pair of spur gears.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IAS-5Ans. (c) In spur gears, the contact between meshing teeth occurs along the entire face
width of the tooth, resulting in a sudden application of the load which, in turn,
results in impact conditions and generates noise.
In helical gears, the contact between meshing teeth begins with a point on the
leading edge of the tooth and gradually extends along the diagonal line across the
tooth. There is a gradual pick-up of load by the tooth, resulting in smooth
engagement and silence operation.
Pitch point
IAS-6.
An imaginary circle which by pure rolling action, gives the same motion as
the actual gear, and is called
[IAS-2000]
(a) Addendum circle
(b) pitch circle
(c) Dedendum circle
(d) base circle
S K Mondals
Chapter 3
IAS-6Ans. (b)
Pressure angle
IAS-7.
Minimum number of teeth for involute rack and pinion arrangement for
pressure angle of 20 is
[IAS-2001]
(a) 18
(b) 20
(c) 30
(d) 34
2h f
sin
2
2 1
= 17.1
sin 2 20o
as > 17
So Tmin = 18
Cycloidal teeth
IAS-9.
The tooth profile most commonly used in gear drives for power
transmission is
[IAS-1996]
(a) A cycloid
(b) An involute
(c) An ellipse (d) A parabola
IAS-9Ans. (b) It is due to easy manufacturing.
Contact ratio
IAS-10.
IAS-11.
(b)
1
x
2
(c) (1 + 2 ) x
(d)
(1 + 2 )
x
[IAS-2002]
S K Mondals
Interference
Chapter 3
IAS-12.
For spur with gear ratio greater than one, the interference is most likely
to occur near the
[IAS-1997]
(a) Pitch point
(b) point of beginning of contact
(c) Point of end of contact
(d) root of the tooth
IAS-12Ans. (d)
IAS-13.
Assertion (A): In the case of spur gears, the mating teeth execute pure rolling
motion with respect to each other from the commencement of engagement to its
[IAS-2003]
termination.
Reason (R): The involute profiles of the mating teeth are conjugate profiles which
obey the law of gearing.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IAS-15Ans. (a)
IAS-16.
Assertion (A): Gears with involute tooth profile transmit constant velocity ratios
between shafts connected by them.
[IAS-1997]
Reason (R): For involute gears, the common normal at the point of contact between
pairs of teeth always passes through the pictch point.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IAS-16Ans. (a)
S K Mondals
IAS-17.
Chapter 3
1
24
(b)
IAS-17Ans. (a)
1
8
(c)
4
15
(d) 12
[IAS-1995]
TA .TC .TE 20 30 25 1
=
=
TB .TD .TF 60 80 75 24
A fixed gear having 100 teeth meshes with another gear having 25 teeth,
the centre lines of both the gears being joined by an arm so as to form an
epicyclic gear train. The number of rotations made by the smaller gear for
one rotation of the arm is
[IAS-1995]
(a) 3
(b) 4
(b) 5
(d) 6
IAS-18Ans. (c)
T
100
=5
Re volution of 25 teeth gear = 1 + 100 (for one rotation of arm) = 1 +
T25
25
IAS-19.
For an epicyclic gear train, the input torque = 100 Nm. RPM of the input
gear is 1000 (clockwise), while that of the output gear is 50 RPM
(anticlockwise). What is the magnitude of the holding torque for the gear
train?
[IAS-2007]
(a) Zero
(b) 500 Nm
(c) 2100 Nm
(d) None of the above
IAS-19Ans. (c) Ti+To+Tarm=0 and Tii + Too + Tarmarm = 0
1000
1 = Ti i 1 =100
1 = 2100 Nm
50
o
No
Gives, Tarm=Ti
IAS-20.
[IAS-2004]
N B NC
T
= A NA = 0
N A NC
TB
N B NC
48
N
=
or B + 1 = 2
NC
NC
24
IAS-20Ans. (a)
IAS-21.
or
NB
= 2 +1 = 3
NC
100 kW power is supplied to the machine through a gear box which uses an
epicyclic gear train. The power is supplied at 100 rad/s. The speed of the
S K Mondals
Chapter 3
output shaft of the gear box is 10 rad/s in a sense opposite to the input
speed. What is the holding torque on the fixed gear of the train?
[IAS-2004]
(a) 8 kNm
(b) 9 kNm
(c) 10 kNm
(d) 11 kNm
IAS-21Ans. (b) T1+T2+T3=0
T1W1+T2W2+T3W3=0
W3=0
T1W1=100kW, W1=100rad/s
T1=1 k Nm
Or T2=
TW
100
1 1
=
= 10kNm
W2
(10 )
T3 = T2 T1 = ( 10 ) 1 = 9kNm
IAS-22.
[IAS-2003]
IAS-22Ans. (d)
Bevel Gears
IAS-23.
Assertion (A): Spiral bevel gears designed to be used with an offset in their shafts
are called hypoid gears
[IAS-2004]
Reason (R): The pitch surfaces of such gears are hyperboloids of revolution.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IAS-23Ans. (a)
Worm Gears
IAS-24.
S K Mondals
IAS-25.
Chapter 3
Speed reduction in a gear box is achieved using a worm and worm wheel.
The worm wheel has 30 teeth and a pitch diameter of 210 mm. If the
pressure angle of the worm is 20o, what is the axial pitch of the worm?
(a) 7 mm
(b) 22 mm
[IAS-2004]
(c) 14 mm
(d) 63 mm
IAS-25Ans. (b)
m=
210
=7
30
and Px = m =
22
7 = 22mm
7
IAS-24.
IAS-24Ans. (a)
IAS-25.
1 + cos( )
1 + cos( + )
1 cos( )
(c)
1 + cos( + )
(a)
1 + cos( + )
1 + cos( )
1 cos( + )
(d)
1 + cos( )
(b)
IAS-Ans. (b)
IAS-26.
Design of Bearings
S K Mondals
4.
Chapter 4
Design of Bearings
Theory at a glance (GATE, IES, IAS & PSU)
Rolling contact bearings are also called anti-friction bearing due to its low friction
characteristics. These bearings are used for radial load, thrust load and combination of
thrust and radial load. These bearings are extensively used due to its relatively lower
price, being almost maintenance free and for its operational ease. However, friction
increases at high speeds for rolling contact bearings and it may be noisy while running.
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.
Due to this low friction offered by rolling contact bearings, these are called
antifriction bearings.
The 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.
3. Accuracy of shaft alignment.
4. Low cost of maintenance, as no lubrication is required while in service.
5. Small overall dimensions.
6. Reliability of service.
7. Easy to mount and erect.
8. Cleanliness.
Disadvantages
Design of Bearings
S K Mondals
Chapter 4
Fig.
Design of Bearings
S K Mondals
Chapter 4
2.
3.
4.
Design of Bearings
S K Mondals
Chapter 4
Design of Bearings
S K Mondals
Chapter 4
Needle Bearings
Needle bearings have very high load ratings and require less space
Design of Bearings
S K Mondals
Chapter 4
According to ISO plan for dimension series bearings are provided with two digit numbers. The
first number indicates the width series 8, 0, 1, 2, 3, 4, 5 and 6 in order of increasing width. The
second number indicate diameter series 7, 8, 9, 0, 1, 2, 3, and 4 in order of ascending outer
diameter of bearing. Thus bearing number SKF 2015, 3115 and 4215 shows bearings
belonging to different series with 75 mm bore diameter but width is increasing. SKF 2015,
3115 and 4215 shows width is increasing ascending outer diameter of bearing same bore
diameter 75 mm. (i.e. 15 5)
The static load rating is the load at which permanent deformation of a race or ball will
occur.
The bearing is not rotating when this measurement is made.
Bearing load
If two groups of identical bearings are tested under loads P1 and P2 for respective lives of L1
and L2, then,
L1 P2
=
L2 P1
Where,
L= life in millions of revolution or life in hours
a = constant which is 3 for ball bearings and 10/3 for roller bearings
C = P (L)
1
a
Design of Bearings
S K Mondals
Chapter 4
0.021
0.21
Pa
e
Pr
X
Y
Pa
e
Pr
X
Y
1.0
0.56
0.0
2.15
0.110
0.30
1.0
0.56
0.0
1.45
0.560
0.44
1.0
0.56
0.0
1.00
The factor, C0 is obtained from the bearing catalogue
Load-life Relationship
Rating Life
Rating life is defined as the life of a group of apparently identical ball or roller bearings, in
number of revolutions or hours, rotating at a given speed, so that 90% of the bearings will
complete or exceed before any indication of failure occur.
Suppose we consider 100 apparently identical bearings. All the 100 bearings are put onto a
shaft rotating at a given speed while it is also acted upon by a load. After some time, one after
another, failure of bearings will be observed. When in this process, the tenth bearing fails,
then the number of revolutions or hours lapsed is recorded. These figures recorded give the
rating life of the bearings or simply L10 life (10 % failure). Similarly, L50 means, 50 % of the
bearings are operational. It is known as median life. Figure below defines the life of rolling
contact bearings.
Design of Bearings
S K Mondals
Chapter 4
Fig.
Rating Life
L = bearing life in (Mrev)
d = dynamic load capacity
R = Equivalent bearing load.
N = speed of rotation
L h = bearing life in (hours)
P = 3 for ball bearing
10
for roller bearing
=
3
d
( i ) L =
R
60 NL h
( ii ) L =
106
R = XFr + YFa
Fr = Radial load, Fa = axial load
The rated life of a ball bearing,
d
L=
R
Where,
d = dynamic load capacity
R = Equivalent bearing load
P = 3 for ball bearing
10
P =
for roller bearing.
3
Reliability of a Bearing
We have already discussed that the rating life is the life that 90 per cent of a group of identical
bearings will complete or exceed before the first evidence of fatigue develops. The reliability
Design of Bearings
S K Mondals
Chapter 4
(R) is defined as the ratio of the number of bearings which have successfully completed L
million revolutions to the total number of bearings under test. Sometimes, it becomes
necessary to select a bearing having a reliability of more than 90%. According to Wiebull, the
relation between the bearing life and the reliability is given as
1 L
log e =
R a
1/b
L
1
= log e
a
R
or
...(i)
Where L is the life of the bearing corresponding to the desired reliability R and a and b are
constants whose values are
b = 1.17
a = 6.84, and
If L90 is the life of a bearing corresponding to a reliability of 90% (i.e. R90), then
1/ b
1
L90
= log e
R 90
Dividing equation (i) by equation (ii), we have
...(ii)
1/b
log e (1 / R )
1/1.17
L
... (b = 1.17 )
=
= * 6.85 log e (1 / R )
L90 log e (1 / R 90 )
This expression is used for selecting the bearing when the reliability is other than 90%.
Note: If there is n number of bearings in the system each having the same reliability R, and
then the reliability of the complete system will be
RS = Rp
Where RS indicates the probability of one out of p number of bearings failing during its life
time.
1/b
log e (1 / R90 )
1/1.17
= log e (1 / 0.90 )
= ( 0.10536 )
0.8547
= 0.146
1/ b
log e (1 / R )
L
=
L90
0.146
1/1.17
= 6.85 log e (1 / R )
C = P (L)
1
a
Design of Bearings
S K Mondals
Chapter 4
Where, C is the basic load rating and P and L are bearing operating load and life
respectively and a is a constant which is 3 for ball bearings and 10/3 for roller
bearings.
Solution:
The L10 life has 90% reliability. Therefore the L10 rated life must be 1800 hr.
Example-2:
A ball bearing is to be selected to withstand a radial load of 4 kN and have an L10 life
of 1200 h at a speed of 600 rev/min. The bearing makers catalog rating sheets are
based on an L10 life 3800 h at 500 rev/min. What load should be used to enter the
catalog?
Given:
Ball bearing must withstand 4 kN for 1200 hr. with a reliability of 90% at a
speed of 600 rev/min. The catalog rating sheets are based on an L10 life of 3800
hr at 500 rev/min.
Find:
Solution:
F1 = 4kN
F2 = ?
L k
L2 F1
= F2 = F1 2
L1 F2
L1
For a ball bearing, k = 3
1/3
114 106
F2 = 4kN *
6
43.2 10
F2 = 5.53 kN
Sample problem
A simply supported shaft, diameter 50mm, on bearing supports carries a load of 10kN at its
center. The axial load on the bearings is 3kN. The shaft speed is 1440 rpm. Select a bearing for
1000 hours of operation.
Solution
D
Design
of Bea
arings
S K Mo
ondals
C
Chapter
r4
Th
he radial looad Pr = 5 kN and ax
xial load Pr = 3 kN. Hence,
H
a sin
ngle row deep groove ball
b
beearing may be chosen as
a radial load is predom
minant. This choice ha
as wide scop
pe, considerring
ne
eed, cost, fu
uture changees etc.
60
0 1440 100
00
= 86.4
Millions
M
of re
evolution forr the bearin
ng, L10 =
6
10
Foor the selecction of bea
aring, a man
nufacturerss catalogue has been consulted.
c
The
T
equivallent
ra
adial load on
n the bearin
ng is given by,
b
Pe = XV
VPr + YPa
Here,
H
V=1.0 (assuming
(
inner
i
race rootating)
Frrom the catalogue, C0 = 19.6 kN foor 50mm inn
ner diameteer.
Pa
3..0
=
= 0.153,
C0 19
9.6
Th
herefore, va
alue of e from
m the table (sample tab
ble is given in the text above) and
By
y linear inte
erpolation = 0.327.
Pa
3
Here,
H
= = 0.6 > e .H
Hence, X and Y values a
are taken frrom fourth ccolumn of th
he
Pr
5
Sa
ample tablee. Here, X= 0.56
0
and Y=
= 1.356
Th
herefore, Pe =XVPr +YP
Pa = 0.561.05.0 + 1.35
563.0 = 6.8
867 kN
1
Now,
N
the tab
ble for singlle row deep
p groove ball bearing of
o series- 02
2 shows tha
at for a 50m
mm
in
nner diametter, the valu
ue of C = 35..1 kN. Therefore, this bearing
b
may
y be selected
d safely for the
giiven requireement witho
out augmen
nting the sha
aft size. A possible
p
bearring could be
b SKF 6210
0.
Sliding
S
Contac
ct Beariings
Depending
D
upon the nature
n
of contact.
c
Th
he bearings under
u
this g
group are cllassified as:
(a) Sliding conttact bearin
ngs, and
(b) Ro
olling conttact bearin
ngs.
n sliding contact bea
arings, as shown
s
in Fig. the slidiing takes pllace along the
t surfacess of
In
co
ontact between the mooving elemen
nt and the fixed eleme
ent. The sliding contacct bearings are
allso known as
a plain bea
arings.
F
Fig.
Design of Bearings
S K Mondals
Chapter 4
The sliding contact bearings, according to the thickness of layer of the lubricant between the
bearing and the journal, may also be classified as follows:
1. Thick film bearings: The thick film bearings are those in which the working surfaces are
completely separated from each other by the lubricant. Such type of bearings is also called as
hydrodynamic lubricated bearings.
2. Thin film bearings: The thin film bearings are those in which, although lubricant is
present; the working surfaces partially contact each other at least part of the time. Such type
of bearings is also called boundary lubricated bearings.
3. Zero film bearings: The zero film bearings are those which operate without any lubricant
present.
4. Hydrostatic or externally pressurized lubricated bearing: The hydrostatic bearings
are those which can support steady loads without any relative motion between the journal and
the bearing. This is achieved by forcing externally pressurized lubricant between the
members.
Conformability: It is the ability of the bearing material to accommodate shaft deflections and
bearing inaccuracies by plastic deformation (or creep) without excessive wear and heating.
Embeddability: It is the ability of bearing material to accommodate (or embed) small
particles of dust, grit etc., without scoring the material of the journal.
D
Design
of Bea
arings
S K Mo
ondals
C
Chapter
r4
F Variatioon of pressu
Fig.
ure in the converging fillm.
Terms
T
u
used
in Hydrodynamic Jourrnal Bea
aring
A hydrodyna
amic journa
al bearing is shown in
n figure beloow, in whicch O is thee centre of the
joournal and O is the cen
ntre of the bearing.
Leet D = Diam
meter of the bearing,
d = Diameterr of the journal,
an
nd
l = Length off the bearing
g.
Th
he following
g terms useed in hydrod
dynamic
joournal bearring are im
mportant frrom the
su
ubject point of view :
1.. Diametra
al clearanc
ce. It the diifference
beetween the diameters of the bearring and
th
he journal.. Mathema
atically, diiametral
clearance,
c=Dd
Fig. Hyd
drodynamic journal bea
aring.
Note:
N
The diametral
d
clearance
c
(c) in a bea
aring shoulld be smalll enough too produce the
ne
ecessary vellocity gradient, so thatt the pressu
ure built up will supporrt the load. Also the sm
mall
clearance hass the advan
ntage of decrreasing sidee leakage. However,
H
thee allowance must be ma
ade
fo
or manufactturing tolerrances in the
t
journal and bushiing. A commonly used
d clearancee in
in
ndustrial ma
achines is 0.025 mm
cit: It is the
t
radial distance
d
beetween the centre (O) of the bea
aring and the
4.. Eccentric
diisplaced cen
ntre (O) of the
t bearing under load. It is denote
ed by e.
5.. Minimum
m oil film thickness:
t
It is the minimum
m
diistance betw
ween the beearing and the
joournal, undeer completee lubrication
n condition
n. It is denooted by h0 and occurs at the linee of
ce
enters as sh
hown in Figu
ure above. Its value ma
ay be assum
med as c / 4.
6.. Attitude or
o eccentriicity rati: It
I is the ratiio of the ecccentricity to the radial clearance.
c
Mathematica
M
ally, attitude
e or eccentrricity ratio,
c h0
h
2h
e
= 1
= 1 0 = 1 0
c1
c1
c1
c
..... ( c1 = c / 2 )
Design of Bearings
S K Mondals
Chapter 4
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.
Notes: 1. when the length of the journal (l) is equal to the diameter of the journal (d), then the
bearing is called square bearing.
2. Because of the side leakage of the lubricant from the bearing, the pressure in the film is
atmospheric at the ends of the bearing. The average pressure will be higher for a long bearing
than for a short or square bearing. Therefore, from the stand point of side leakage, a bearing
with a large l / d ratio is preferable. However, space requirements, manufacturing, tolerances
and shaft deflections are better met with a short bearing. The value of l / d may be taken as 1
to 2 for general industrial machinery. In crank shaft bearings, the l / d ratio is frequently less
than 1.
Somerfield Number
The Somerfield number is also a dimensionless parameter used extensively in the design of
journal bearings. Mathematically,
Sommerfeld number =
N d
P c
N d
= 14.3 106
p c
*Coefficient of friction,
33 N d
f=
+ k
108 p c
... (when
From Figure below, we see that the minimum amount of friction occurs at A and at this point
the value of N / p is known as bearing modulus which is denoted by K. The bearing should
not be operated at this value of bearing modulus, because a slight decrease in speed or slight
increase in pressure will break the oil film and make the journal to operate with metal to
metal contact. This will result in high friction, wear and heating. In order to prevent such
conditions, the bearing should be designed for a value of N / p at least three times the
minimum value of bearing modulus (K). If the bearing is subjected to large fluctuations of load and
heavy impacts, the value of
N / p is greater than K, then the bearing will operate with thick film lubrication or under
hydrodynamic conditions. On the other hand, when the value of N / p is less than K, then the oil film
value of
D
Design
of Bea
arings
S K Mo
ondals
C
Chapter
r4
N /p.
Tempe
T
rature Rise
Th
he heat gen
nerated in a bearing is due
d to the flluid friction
n and friction
n of the parrts having
re
elative motion. Mathem
matically, heeat generateed in a bearring,
Qg = .W.V
W N-m/s or
o J/s or watts
Where
W
= Coeffficient of friction,
W = Load
d on the bearring in N, = Pressure on the bearin
ng in N/mm
m2 Projecteed
2
area of the
e bearing in
n mm = p (l d),
d.N
V = Rubbiing velocity in m/s =
, d is in meters, and
6
60
N = Speed
d of the journ
nal in r.p.m
m.
Qd = C.A
C (tb ta) J/s or
o W
... ( 1 J/s = 1 W)
W
Design of Bearings
S K Mondals
Chapter 4
Notes: 1. for well designed bearing, the temperature of the oil film should not be more than
60C, otherwise the viscosity of the oil decreases rapidly and the operation of the bearing is
found to suffer. The temperature of the oil film is often called as the operating temperature of
the bearing.
2. In case the temperature of the oil film is higher, then the bearing is cooled by circulating
water through coils built in the bearing.
3. The mass of the oil to remove the heat generated at the bearing may be obtained by
equating the heat generated to the heat taken away by the oil. We know that the heat taken
away by the oil,
Qt = m.S.t J/s or watts
Where
m = Mass of the oil in kg / s,
S = Specific heat of the oil. Its value may be taken as 1840 to 2100 J / kg / C,
t = Difference between outlet and inlet temperature of the oil in C.
Bearing Materials
The materials commonly used for sliding contact bearings are discussed below:
1. Babbit metal: The tin base and lead base babbits are widely used as a bearing material,
because they satisfy most requirements for general applications. The babbits are
recommended where the maximum bearing pressure (on projected area) is not over 7 to 14
N/mm2. When applied in automobiles, the babbit is generally used as a thin layer, 0.05 mm to
0.15 mm thick, bonded to an Insert or steel shell. The composition of the babbit metals is as
follows:
Tin base babbits: Tin 90%; Copper 4.5%; Antimony 5%; Lead 0.5%.
Lead base babbits: Lead 84%; Tin 6%; Antimony 9.5%; Copper 0.5%.
2. Bronzes:
3. Cast iron:
4. Silver:
5. Non-metallic bearings:
Design of Bearings
S K Mondals
Chapter 4
6. Soft rubber
N d
P c
R = Radius of bearing
r = Radius of journal
e = eccentricity
h0 = minimum film thickness.
= eccentricity ratio.
= viscosity N S
mm2
P = unit bearing pressure Load per unit
projection area. ( W / ld ) N / mm2
ns = journal speed
f = co- efficient of friction
(vii) C = ( 0.001 ) r
(viii) h 0 = ( 0.0002 ) r
1
1 N S
P=
= 109 N S
mm2
100
1000 m2
2ns fwr
(x) Frictional power ( KW )f =
106
w = Force
(ix) 1CP =
w x r = Torque
wr ( ) = p
= wr2rs .
(xi) Flow variable (FV) =
Q
nsCrl
r
(xii) co efficient of friction variable: CFV = f
c
(xiii) The angle of eccentricity or attitude angle locates the position of minimum film thickness
with respect to the direction of load.
N
is called bearing characteristic Number
(xiv)
P
= absolute viscosity of the lubricant
N = speed, P = Bearing pressure
N
should
(xv) When bearing is subjected to large fluctuation of load and heavy impacts. The
P
be 15 times the bearing modulus
Design of Bearings
S K Mondals
Chapter 4
Load-life Relationship
GATE-2. The rated life of a ball bearing varies inversely as which one of the
following?
[GATE-1993; IES-2004]
(a) Load
(b) (load)2
(c) (load)3
(d) (load)3.33
P
GATE-2Ans. (c)
d
L = , d = dynamic load capacity
R
10
for roller bearing.
3
GATE-3. The life of a ball bearing at a load of 10 kN is 8000 hours. Its life in hours, if
the load is increased to 20 kN, keeping all other conditions the same, is
(a) 4000
(b) 2000
(c) 1000
(d) 500 [GATE-2000]
GATE-3 Ans. (c)
1
Life
P
P
10
L2 = L1 1 = 8000 = 1000 hrs.
P
20
2
GATE-4. The dynamic load capacity of 6306 bearing is 22 kN. The maximum radial
load it can sustain to operate at 600 rev/min, for 2000 hours is [GATE-1997]
(a) 4.16 kN
(b) 3.60 kN
(c) 6.2S kN
(d) 5.29 kN
GATE-4 Ans. (d)
Design of Bearings
S K Mondals
Chapter 4
s=
zn D
.
P Cd
25 20 20 10 3
S=
3
0.8 106
50 10
= 0.125
GATE-8. To restore stable operating condition in a hydrodynamic journal bearing,
when it encounters higher magnitude loads,
[GATE-1997]
(a) Oil viscosity is to be decreased
(b) oil viscosity is to be increased
(c) Oil viscosity index is to be increased
(d) oil viscosity index is to be
decreased
GATE-8Ans. (b)
GATE-9.
List l
List II
[GATE-1997]
(A) Automobile wheel mounting on axle 1. Magneto bearing
(B) High speed grinding spindle
2. Angular contact bearing
(C) I.C. Engine connecting rod
3. Taper roller bearing
(D) Leaf spring eye mounting
4. Hydrodynamic journal bearing
Design of Bearings
S K Mondals
Chapter 4
5. Sintered metal bearing
6. Teflon/Nylon bush.
[GATE-1992]
2 1500
or =
30 0.01
Design of Bearings
S K Mondals
Types of Rolling Contact Bearings
Chapter 4
IES-3.
IES-5.
Match List I (Type of Bearings) with List II (Type of Load) and select the
correct answer using the code given below the Lists:
[IES-2005]
List I
List II
A Deep groove bearing
1. Radial load
B. Tapered roller bearing
2. Radial and axial load
C. Self aligning being
3. Mainly radial load with shaft misalignment
D. Thrust bearing
4. Mainly axial load
Design of Bearings
S K Mondals
A
(a) 1
(c) 1
IES-6Ans. (a)
B
2
4
Chapter 4
C
3
3
D
4
2
(b)
(d)
A
3
3
B
4
2
C
1
1
D
2
4
IES-7.
[IES-2004]
IES-8.
[IES-2003]
[IES-1992]
Design of Bearings
S K Mondals
Chapter 4
IES-13.
IES-15.
Load-life Relationship
IES-17.
The rated life of a ball bearing varies inversely as which one of the
following?
[GATE-1993; IES-2004]
(a) Load
(b) (load)2
(c) (load)3
(d) (load)3.33
P
d
L= ,
R
10
for roller bearing.
3
[IES-2005]
Design of Bearings
S K Mondals
Chapter 4
IES-20.
Match List-I (Bearings) with List-II (Applications) and select the correct
answer using the codes given below the lists:
[IES-2001]
List I
List II
A. Cylindrical roller
1. Radial loads
B. Ball-bearing
2. Machine needs frequent dismantling
and assembling
C. Taper rolling bearing
3. Radial loads with lesser thrust
D. Angular contact ball-bearing
4. Shock loads
5. Axial expansion of shaft due to rise in
temperature
A
B
C
D
A
B
C
D
(a) 4
3
1
5
(b)
1
3
2
5
(c) 4
1
2
3
(d)
5
4
1
3
IES-21Ans. (c)
IES-22.
Match List-I with List-II and select the correct answer using the codes
given below the lists:
[IES-1998]
List I
List II
A. End thrust
1. Plain bearing
B. No cage
2. Ball bearing
C. More accurate centering
3. Needle bearing
D. Can be overloaded
4. Tapered roller bearing
Code:
A
B
C
D
A
B
C
D
(a)
3
4
2
1
(b)
4
3
1
2
(c)
3
4
1
2
(d)
4
3
2
1
IES-22 Ans. (d)
IES-23.
Match List-I with List-II and select the correct answer using the codes
given below the Lists:
[IES-1997]
List-I
List-II
Design of Bearings
S K Mondals
Chapter 4
(Bearing)
A. Ball bearing
B. Tapered Roller bearings
C. Spherical Roller bearings
D. Needle Roller bearings
Codes:
A
B
C
D
(a)
4
1
3
2
(c)
2
3
1
4
IES-23 Ans. (d)
(Purpose)
1. Heavy loads with oscillatory motion
2. Light loads
3. Carrying both radial and thrust loads
4. Self-aligning property
A
B
C
D
(b)
2
1
4
3
(d)
2
3
4
1
IES-24.
In a collar thrust bearing, the number of collars has been doubled while
maintaining coefficient of friction and axial thrust same. It will result in
(a) Same friction torque and same bearing pressure
[IES-2002]
(b) Double friction torque and half bearing pressure
(c) Double friction torque and same bearing pressure
(d) Same friction torque and half bearing pressure
IES-25 Ans. (d)
Which of the following are included in the finishing operations for porous
bearing?
[IES-2005]
1. Infiltration 2. Sizing
3. Heat treatment 4.Coining
Select the correct answer using the code given below:
(a) 1 and 2
(b) 2 and 3
(c) 2 and 4
(d) 1 and 4
IES-26Ans. (a)
Design of Bearings
S K Mondals
Chapter 4
N S
r
P
c
(ii) c ;
(i) ;
(iii) Ns
IES-31.
unchanged. Since,S =
p c
Since S remains the same even after doubling the speed as well as load and film
Thickness depends on the Sommerfeld number.
IES-33.
Design of Bearings
S K Mondals
Chapter 4
In a journal bearings, the radius of the friction circle increases with the
increase in
[IES-1997]
(a) Load
(b) Radius of the journal
(c) Speed of the journal
(d) Viscosity of the lubricant
IES-35Ans. (b)
IES-36.
DN
60t
DL =
2 D 2 NL
60t
IES-37.
It is seen from the curve that there is a minimum value of the coefficient of
friction () for a particular value of the Bearing Characteristic Number
denoted by . What is this value of the Bearing Characteristic Number
called?
[IES-2004]
(a) McKee Number
(b) Reynolds Number
(c) Bearing Modulus
(d) Somerfield Number
IES-38Ans. (c)
Assertion (A): In equilibrium position, the journal inside a journal bearing
remains floating on the oil film.
[IES-1995]
Reason (R): In a journal bearing, the load on the bearing is perpendicular to the
axis of the journal.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-39Ans. (b) Both A and R are true but R is not correct explanation for A.
IES-39.
IES-40.A full journal bearing having clearance to radius ratio of 1/100, using a
lubricant with =2810-3 Pa s supports the shaft journal running at N = 2400
r.p.m. If bearing pressure is 1.4 MPa, the Somerfield number is [IES-2001]
(a) 810-3
(b) 810-5
(c) 0.48
(d) 0.4810
IES-40Ans. (a) s =
Ns r
p c
Design of Bearings
S K Mondals
Chapter 4
IES-41.
Match List I with List II and select the correct answer using the code given
below the lists:
[IES-1995]
List I (Requirement)
List II (Type)
A. High temperature service
1. Teflon bearing.
B. High load
2. Carbon bearing
C. No lubrication
3. Hydrodynamic bearing
D. Bushings
4. Sleeve bearing
Codes: A
B
C
D
A
B
C
D
(a)
1
2
3
4
(b)
4
1
2
3
(c)
2
1
3
4
(d)
2
3
1
4
IES-44Ans. (d)
Assertion (A): In anti-friction bearings, the frictional resistance is very low as the
shaft held by it remains in floating condition by the hydrodynamic pressure
developed by the lubricant.
[IES-2006]
Reason (R): In hydrodynamic journal bearings, hydrodynamic pressure is
developed because of flow of lubricant in a converging -diverging channel
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES-45Ans. (d)
IES-45.
IES-46.
Design of Bearings
S K Mondals
Chapter 4
(a) Journal speed is low, unit pressure on the bearing is high and viscosity of
[IES-2006]
lubricant used is low
(b) Journal speed is low, unit pressure on the bearing is low and viscosity of
lubricant used is low
(c) Journal speed is high, unit pressure on the bearing is high and viscosity of
lubricant used is high
(d) Appropriate combination of journal speed, unit pressure on bearing and
lubricant viscosity exists resulting in low coefficient of friction
IES-46Ans. (c)
IES-47.
IES-50.
Match List-I (Type of Anti-friction bearing) with List-II (Specific Use) and
select the correct answer using the code given below the Lists: [IES-2006]
List-I
List -II
A. Self-aligning ball bearing
1. For pure axial load
Design of Bearings
S K Mondals
Chapter 4
IES-52.
Design of Bearings
S K Mondals
Chapter 4
Load-life Relationship
IAS-2.
If k = 3 for ball bearings and k = 3.33 for roller bearings, which one of the
following correctly states the load (P) - Life (L) relationship for rolling
contact bearings?
[IAS-2004]
L P
(c) 2 = 1
L1 P2
L P ( k 1)
(b) 2 = 1
L1 P2
L P
(d) 2 = 1
L1 P2
L P
(a) 1 = 1
L2 P2
k 1
IAS-2Ans. (c)
K
d
L = [ d=dynamic load carrying capacity and R= Equivalent load]
R
1
L K
R
L R
2 = 1
L1 R2
Match List-I (Applications) with List-II (Choice of Bearings) and select the
correct answer using the codes given below the lists:
[IAS-2004]
List I
List - II
(Applications)
(Choice of Bearings)
A. Granite table of a coordinate
1. Hydrodynamic bearing
measuring machine
B. Headstock spindle of a lathe
2. Deep groove ball bearing
C. Crank shaft of a diesel engine
3. Hydrostatic bearing
D. Armature of 0.5 kW induction motor 4. Taper roller bearing
Codes:
A
B
C
D
A
B
C
D
(a)
1
4
3
2
(b)
3
2
1
4
(c)
1
2
3
4
(d)
3
4
1
2
IAS-4Ans. (a)
IAS-5.
Design of Bearings
S K Mondals
Chapter 4
load
150
=
= 0.15kN / cm2
projected area 25 40
IAS-8Ans. (c)
IAS-9.
IAS-11.
Thrust bearings of the sliding type are often provided with multiple
sector-shaped bearing pads of the tilting type instead of a continuous
angular bearing surface in order to
[IAS 1994]
(a) Distribute the thrust load more non-uniformly
(b) Provide limited adjustments to shaft misalignments
Design of Bearings
S K Mondals
Chapter 4
The most suitable bearing for carrying very heavy loads with slow speed is
(a) Hydrodynamic bearing
(b) ball bearing
[IAS 1994]
(c) Roller bearing
(d) hydrostatic bearing
IAS-12 Ans. (d)
Match List -I (Bearings) with List-II (Applications) and select the correct
answer using the codes given below the lists:
[IAS-1998]
List I
List-II
A. Journal bearing
1. Electric motors
B. Thrust bearing
2. Watches
C. Conical pivot bearing
3. Marineengines
D. Ball bearing
4. Swivelling chairs
Codes:
A
B
C
D
A
B
C
D
(a)
3
4
1
2
(b)
4
2
1
3
(c)
3
4
2
1
(d)
4
2
3
1
IAS-13Ans. (c)
Design of Bearings
S K Mondals
Chapter 4
S K Mondals
5.
Chapter 5
Fluctuating Load
Consideration for Design
Objective Questions (IES, IAS, GATE)
Stress Concentration
Origin of stress concentration
Machine members often have regions in which the state of stress is significantly greater than
theoretical predictions as a result of:
1. Geometric discontinuities or stress raisers such as holes, notches, and fillets;
2. Internal microscopic irregularities (non-homogeneities) of the material created by such
manufacturing processes as casting and molding;
3. Surface irregularities such as cracks and marks created by machining operations.
These stress concentrations are highly localized effects which are functions of geometry and
loading. In this tutorial, we will examine the standard method of accounting for stress
concentrations caused by geometric features. Specifically, we will discuss the application of a
theoretical or geometric stress-concentration factor for determination of the true state of stress
in the vicinity of stress raisers.
S K Mondals
Chapter 5
Kt =
max
ave
It is possible to predict the stress concentration factors for certain geometric shapes using
theory of elasticity approach. For example, for an elliptical hole in an infinite plate, subjected
to a uniform tensile stress 1 (figure below), stress distribution around the discontinuity is
disturbed and at points remote from the discontinuity the effect is insignificant. According to
such an analysis
2b
3 = 1 1 +
a
Stress concentration due to a central elliptical hole in a plate subjected to a uni-axial loading.
In design under fatigue loading, stress concentration factor is used in modifying the values of
endurance limit while in design under static loading it simply acts as stress modifier. This
means Actual stress= kt calculated stress.
For ductile materials under static loading effect of stress concentration is not very serious but
for brittle materials even for static loading it is important.
Fluc
ctuatin
ng Load
d Consideratio
on for D
Design
S K Mo
ondals
C
Chapter
r5
Brittle
B
Matterials
Stress-conce
S
entration facctors are alw
ways requirred for brittlle materialss, regardlesss of the
lo
oading condiitions, since
e brittle failu
ure results in fracture. This type oof failure is characteristic
off brittle matterials which do not exh
hibit a yield
ding or plasttic range. A
As a consequ
uence of britttle
frracture, the part breakss into two orr more piecees having no
o load carry
ying capabillity. To avoid
su
uch catastroophic failuree, the design
n practice iss to always use
u a stresss-concentrattion factor ffor
brrittle materials to ensu
ure that the state of streess is accurately repressented.
erial Practtice: max = K t 0
Brittle Mate
Methods
M
s of red
ducing stress concen
ntration
n
A number of methods arre available to reduce sttress concen
ntration in m
machine parts. Some off
th
hem are as follows:
f
1.. Provide a fillet
f
radius so that thee cross-sectioon may chan
nge graduallly.
2.. Sometimess an elliptica
al fillet is allso used.
3.. If a notch is
i unavoidab
ble it is bettter to provid
de a number of small n
notches rath
her than a loong
one. This reduces thee stress conccentration to
t a large ex
xtent.
4.. If a projecttion is unav
voidable from
m design con
nsiderations it is preferrable to proovide a narroow
notch tha
an a wide no
otch.
5.. Stress relieeving groove are somettimes provid
ded.
Th
hese are dem
monstrated
d in figure beelow.
Fluctuatting Loa
ad Considerattion forr Design
S K Monda
M
als
Chapte
er 5
Fluctu
uating Stresse
S
es
Types of flluctuating stress
s
h vary from
m a minimum value to a maximum
m value of the same nature,
n
1. The strresses which
(i.e. tensile
e or compre
essive) are called fluctu
uating stressses.
2. The stre
esses which
h vary from zero to a cerrtain maxim
mum value a
are called re
epeated streesses.
esses which
h vary from a minimum
m value to a maximum value of the opposite nature
n
3. The stre
(i.e. from a certain minimum
m
coompressive tto a certain
n maximum
m tensile or from a min
nimum
tensile to a maximum
m compressiv
ve) are calleed alternating stresses..
Cyclic Stressing
S
g
As the nam
me implies, the induceed stresses v
vary in som
me pattern w
with time. This
T
can be due to
variation in
i the applied load itself or becau
use of the conditions
c
of use as seeen earlier. Let
L us
assume th
hat the patttern of such
h a variatioon is sinusooidal. Then
n the following are thee basic
terminolog
gy associateed with varriable stressses. The deffinitions inccluded heree are elemeentary.
They are introduced
i
for
f clarity an
nd convenieence.
m stress: ( max )
Maximum
The largesst or highestt algebraic value
v
of a sttress in a sttress cycle. P
Positive for tension
Minimum
m stress: ( max )
The smallest or lowesst algebraic value of a stress
s
in a stress cycle. Positive forr tension.
Nominal stress: ( noom )
As obtain
ned or calcu
ulated from
m simple th
heory in tension, bend
ding and toorsion negllecting
geometric discontinuiities
Fluc
ctuatin
ng Load
d Consideratio
on for D
Design
S K Mo
ondals
C
Chapter
r5
nom
r M / Z or T.r / J
m = F / A or
Fmin
Mean
M
stresss (Mid ran
nge stress):: (m)
minimum
m
strress in one cycle.
c
A
The a
algebraic meean or averrage of the Maximum
M
a
and
+ min
max
m
2
Sttress range: (r) the allgebraic diffference betw
ween the ma
aximum and
d minimum stress in on
ne
cy
ycle.
r = m
max min
m =
min
a = max
= r
2
2
Types
T
o Variations
of
(a
a) (Comple
etely) rever
rsible stres
ssing:
Sttress variattion is such
h that the mean streess is zero; same mag
gnitude of maximum
m
a
and
minimum
m
strress, one in tension an
nd the otherr in compresssion. Now for Comple
etely reversiible
lo
oading m = max = min; R = - 1 and A = 0
(b
b) Repeated stressing
g:
Sttress variattion is such that the miinimum streess is zero. Mean and amplitude
a
s
stress
have the
sa
ame value foor repeated loading
miin = 0
= a = max/2
R=0a
and A = 1
Fluctuatting Loa
ad Considerattion forr Design
S K Monda
M
als
Chapte
er 5
(c) Fluctu
uating stre
essing:
Both minimum and maximum
m
sttresses are positive
p
and
d mean stresss also being positive
(tensile)
(d) Altern
nating stre
essing:
Positive maximum
m
strress and negative miniimum stresss; mean streess is genera
ally positivee but
can also bee negative.
Endurance Limit
Endura
ance or Fatigue Limit
In the case of the steeels, a knee (flattening or
o saturatioon) occurs in
n the graph
h, and beyon
nd this
knee failurre will not occur,
o
no ma
atter how la
arge the num
mbers of cyccles are. The strength ((stress
amplitudee value) corrresponding to the kneee is called the endura
ance limit (S
Se) or the ffatigue
limit. How
wever the graph
g
neverr does becoome horizon
ntal for non
n-ferrous metals
m
and alloys,
a
hence thesse materialss do not hav
ve an endurance limit.
Endurrance or
o Fatigu
ue limitt - defin
nition
S K Mondals
Chapter 5
Endurance or fatigue limit can be defined as the magnitude of stress amplitude value at or
below which no fatigue failure will occur, no matter how large the number of stress reversals
are, in other words leading to an infinite life to the component or part being stressed. For most
ferrous materials Endurance limit (Se) is set as the cyclic stress level that the material can
sustain for 10 million cycles.
In general, steel alloys which are subjected to a cyclic stress level below the EL (properly
adjusted for the specifics of the application) will not fail in fatigue. That property is commonly
known as "infinite life". Most steel alloys exhibit the infinite life property, but it is interesting
to note that most aluminum alloys as well as steels which have been casehardened by
carburizing, do not exhibit an infinite-life cyclic stress level (Endurance Limit).
Factors Influencing Fatigue
(i) Loading
Nature and type of loading: - Axial tension, bending, torsion and combined loading-Mean and
Variable components in case of Repeated, Fluctuating and Alternating loading and Frequency
of loading and rest periods
(ii) Geometry
Size effects and stress concentration
(iii) Material
Composition, structure, directional properties and notch sensitivity
(iv) Manufacturing
Surface finish, heat treatment, residual stresses
(V) Environment
Corrosion, high temperature, radiation
Material
As noted earlier there are two classes of materials as for as the fatigue behavior is concerned,
those material which exhibit well defined endurance limit and those without do not show
endurance limit. Most ferrous materials and basic steels fall under the first category and some
heat treated alloys of steel, aluminum etc. fall under the second category.
Composition and strength of the material are interrelated and detail discussion on strength
follows later. Strength is also related to micro structure and in this respect it is interesting to
note that soft structure like ferrite resist fatigue better than hard structure like cementite.
However because of the higher strength that can be achieved from the same material by
altering the micro structure, such structures are preferred in spite of their poor resistance
Why is the surface so important?
Fatigue failures almost always begin at the surface of a material. The reasons are that (a) the
most highly-stresses fibers are located at the surface (bending fatigue) and (b) the
intergranular flaws which precipitate tension failure are more frequently found at the surface.
Suppose that a particular specimen is being fatigue tested (as described above). Now suppose
the fatigue test is halted after 20 to 25% of the expected life of the specimen and a small
thickness of material is machined off the outer surface of the specimen, and the surface
condition is restored to its original state. Now the fatigue test is resumed at the same stress
level as before. The life of the part will be considerably longer than expected. If that process is
repeated several times, the life of the part may be extended by several hundred percent,
limited only by the available cross section of the specimen. That proves fatigue failures
originate at the surface of a component.
S K Mondals
Chapter 5
Frequency: v or f in units of Hz. For rotating machinery at 3000 rpm, f = 50 Hz. In general
only influences fatigue if there are environmental effects present, such as humidity or elevated
temperatures
Waveform: Is the stress history a shine wave, square wave, or some other wave form? As with
frequency, generally only influences fatigue if there are environmental effects.
kb Size factor
kc Load factor
kd Temperature factor
ke Miscellaneous effects factor
Notch Sensitivity
Geometric Stress Concentration
Factors
Kt =
max
nom
nom =
F
A0
A0 = (w d ) t
Geometric stress concentration factors can be used to estimate the stress amplification in the
vicinity of a geometric discontinuity.
S K Mondals
Chapter 5
Kf =
Kf =
Kf is normally used in fatigue calculations but is sometimes used with static stresses.
Convenient to think of Kf as a stress concentration factor reduced from Kt because of
lessened sensitivity to notches.
If notch sensitivity data is not available, it is conservative to use Kt in fatigue calculations.
Notch Sensitivity Factor
The notch sensitivity of a material is a measure of how sensitive a material is to notches or
geometric discontinuities.
Fluctuatting Loa
ad Considerattion forr Design
S K Monda
M
als
q=
Chapte
er 5
Kf 1
0 q 1
Kt 1
K f = 1 + q ( K t 1) 1 K f K t
It is foun
nd that som
me materia
als are nott very sen
nsitive to th
he existencce of notch
hes or
discontinu
uity. In such
h cases it is not necessa
ary to use th
he full valuee of kt and instead
i
a reeduced
value is neeeded. This is given by a factor known as fatig
gue strength
h reduction factor kf an
nd this
is defined as
Kf =
Endura
ance lim
mit of notcch free sp
pecimens
Endu
urance lim
mit of nottched specimens
q=
Kf 1
K t 1
1
The value
e of q usua
ally lies beetween 0 an
nd 1. If q = 0, kf =1 and this in
ndicates no notch
sensitivity
y. If however q = 1, then
n kf = kt and
d this indica
ates full nottch sensitiviity. Design charts
for q can be found in design han
nd-books and
d knowing
kt, kf may be obtained
d. A typical set of notch
h sensitivity
y curves for ssteel is
q=
1/2
a
1+
r
Fluc
ctuatin
ng Load
d Consideratio
on for D
Design
S K Mo
ondals
C
Chapter
r5
Low
L
& High
H
Cy
ycle Fattigue; F
Finite and
a
Infin
nite Liffe
problem
p
m
Low
L
Cyc
cle Fatiigue
Th
he body of knowledge
k
a
available
on
n fatigue faiilure from N = 1 to N = 1000 cyclles is genera
ally
classified as low-cycle
l
fa
atigue.
High
H
Cy
ycle Fattigue
High-cycle
H
fa
atigue, then
n, is concern
ned with faiilure corresp
ponding to stress cyclees greater th
han
10
03 cycles. (N
Note that a stress
s
cycle (N=1) consttitutes a sin
ngle applicattion and rem
moval of a looad
an
nd then anoother appliccation and removal
r
of looad in the opposite
o
dirrection. Thu
us N= mea
ans
th
hat the load is applied once
o
and then removed
d, which is th
he case with
h the simple
e tensile tesst.)
Finite
F
an
nd Infin
nite Life
e
We
W also distinguish a fin
nite-life and
d an infinitee-life region.. Finite life region coverrs life in terrms
off number of
o stress rev
versals uptto the kneee point.(in case
c
of steeels) beyond
d which is the
in
nfinite-life region.
r
The boundary between
b
theese regions cannot be clearly defiined except for
sp
pecific mate
erials; but itt lies somew
where betw
ween 106 and
d 107 cycless, for materrials exhibitting
fa
atigue limit.
Fatigue
F
with fin
nite life
e
Th
his applies to most com
mmonly used machine parts
p
and th
his can be a
analyzed by
y idealizing the
S--N curve forr, say, steel,,
Th
he line betw
ween 103 an
nd 106 cycless is taken too represent high cycle ffatigue with
h finite life and
a
th
his can be giiven by
logS = b
blogN + c
Where
W
S is th
he reversed stress and b and c are constants.
Fluctuatting Loa
ad Considerattion forr Design
S K Monda
M
als
Chapte
er 5
blog103
This gives
E
EF DB
=
A
AE AD
Or
log
l 10 N 3
63
=
log10 490
4 log10 1
100 log10 490
4 log10 70
0
orr N = 28191
14 cycles.
Soderrberg an
nd Goo
odman Diagram
D
ms
There are several way
ys in which problems in
nvolving thiis combination of stressses may be
solved, butt the followiing are imp
portant from
m the subjectt point of view:
1. Gerber method
2. Goodma
an method and
a
3. Soderbeerg method.
S K Mondals
Chapter 5
1.
Goodman criterion:
a m
1
+
=
e ut FS
2.
Soderberg criterion:
a m
1
+
=
FS
e y
3.
Gerber criterion:
FS a
Where,
( a / Se )
+ ( m / Sut ) = 1 / n 2
2
Goodman Diagram
FS m
+
=1
ut
Fluctuatting Loa
ad Considerattion forr Design
S K Monda
M
als
Chapte
er 5
Goodman method
1
= m+ v
F .S. u e
Where
F.S. = Facto
or of safety,
m = Mean stress,
u = Ultimate stress,
v = Variab
ble stress,
e = Endurrance limit ffor reversed
d loading,
Above exp
pression does not includ
de the effectt of stress cooncentration
n. It may bee noted that for
ductile ma
aterials, the
e stress conccentration m
may be ignorred under stteady loads.
For high stress
s
concen
ntration thee fatigue strress concenttration factoor (Kf) is use
ed to multip
ply
the variab
ble stress.
m v K f
1
=
+
F .S. u
e
Where
F.S. = Facto
or of safety,
m = Mean stress,
u = Ultimate stress,
v = Variab
ble stress,
Fluc
ctuatin
ng Load
d Consideratio
on for D
Design
S K Mo
ondals
C
Chapter
r5
e = Enduran
nce limit for reversed loading, and
K f = Fatigue stress
s
conceentration facctor.
d
sho
owing a Goodman failurre line and h
how a load line
l
is used to
Fiig. Designerrs fatigue diagram
deefine failuree and safety
y in preloade
ed bolted joiints in fatig
gue. Point B represents non-failuree;
pooint C, failu
ure.
Soderbe
S
erg Diagram
1
= m + v
F.S. y e
S K Mondals
Chapter 5
Kf
1
= m+ v
F.S. y
e
Example: A forged steel link with uniform diameter of 30 mm at the centre is
subjected to an axial force that varies from 40 kN in compression to 160 kN in
tension. The tensile (Su), yield (Sy,) and corrected endurance (Se) strength of the
steel material are 600 MPa, 420 MPa and 240 MPa respectively. The factor of safety
against fatigue endurance as per Soderbergs criterion is
Solution:
160 103 N
= 226 MPa
302
2
mm
4
40 103 N
min =
= 56.6 MPa
302
2
mm
4
( + min ) = 84.7 MPa
m ean = max
2
( min ) = 141.3 MPa
min = max
2
1
Therefore
= mean + v
FOS
y
e
max =
1
84.7 141.3
=
+
FOS 420
240
or FOS = 1.26
or
Q.
Hence, we have both stress amplitude and mean stress value of equal magnitude, e .
2
Therefore, the endurance limit representation in Soderberg diagram changes to e , e .
2 2
S K Mondals
Chapter 5
S K Mondals
Chapter 5
3 = 1 1 +
If a=b the hole reduces to a circular one and therefore 3 = 31 which gives k t
a
=3.
GATE 2. Match 4 correct pairs between list I and List II for the questions
List I
List II
[GATE-1994]
(a) Strain rosette
1. Critical speed
(b) Beams
2. Mohr's circle
(c) Section modulus
3. Coil springs
(d) Wahl's stress factor
4. Flexural rigidity
(e) Fatigue
5. Endurance limit
(f) Somerfield number
6. Core section
GATE 2. Ans. (a) 2, (c) 4, (d) 3, (e) - 5
GATE 3. In terms of theoretical stress concentration factor (Kt) and fatigue stress
concentration factor (Kf), then notch sensitivity 'q' is expressed as
[GATE-2004]
(a)
( K f 1)
( K t 1)
(b)
( K f 1)
( K t + 1)
(c)
( K t 1)
( K f 1)
(d)
( K f + 1)
( K t + 1)
S K Mondals
Chapter 5
1max =
1m = 300 MPa
2 m = 300 MPa
1a = 100 MPa
2 a = 100 MPa
Equivalent Stresses
1m e = 12m + 22m 1m 2m
= 3002 + 3002 300 300
= 300 MPa
Similarly,
100 300 1
+
=
400 800 n
n = 1.6
40 103 N
= 56.6 MPa
302
2
mm
4
( + min )
mean = max
= 84.7 MPa
2
( min )
min = max
= 141.3MPa
2
min =
S K Mondals
Therefore
Chapter 5
1
= mean + v
FOS
y
e
1
84.7 141.3
=
+
FOS 420 240
or FOS = 1.26
or
GATE 6. The yield strength of a steel shaft is twice its endurance limit. Which of the
following torque fluctuation represent the most critical situation
according to Soderberg criterion?
[GATE-1993]
(a) -T to +T
(b) -T/2 to +T
(c) 0 to +T
(d) +T/2 to +T
GATE 6. Ans. (a)
GATE 7. An aeroplane makes a half circle towards left. The engine runs clockwise
when viewed from the rear. Gyroscopic effect on the aeroplane causes the
nose to
[GATE-1995]
(a) Lift
(b) dip
(c) both Lift and dip (d) None of the above
GATE 7. Ans. (a)
GATE 8. For a disk of moment of inertia I the spin and precession angular
velocities are and p respectively. The magnitude of gyroscopic couple
is
[GATE-1994]
(a) Ip
(b) Ip / 2
(c) 2Ip
(d) 4Ip
GATE 8. Ans. (a)
GATE 9. The S-N curve for steel becomes asymptotic nearly at
[GATE-2004]
(a) 103 cycles
(b) 104 cycles
(c) 106 cycles
(d) 109 cycles
GATE 9. Ans. (c)
GATE10. A cylindrical shaft is subjected to an alternating stress of 100 MPa. Fatigue
strength to sustain 1000 cycles is 490 MPa. If the corrected endurance
strength is 70 MPa, estimated shaft life will be
[GATE-2006]
(a) 1071 cycles (b) 15000 cycles
(c) 281914 cycles
(d) 928643 cycles
GATE 10. Ans. (c)
It is a finite life problem. The line AB is the failure line. Where A {3, log10 ( 0.9ult )}
but here it will be A {3, log10 ( 490 )} and B{6, log10 ( e )} here it is B{6, log10 ( 70 )}
Therefore F{, log10 N, log10 (100 )} we have to find N
S K Mondals
Chapter 5
EF DB
=
AE AD
log10 N 3
63
Or
=
log10 490 log10 100 log10 490 log10 70
or N = 281914 cycles.
[IES-2000]
Fluctuating Stresses
IES 2.
In designing a shaft for variable loads, the S.N. diagram can be drawn by
(a) Joining the Sut at 0 cycles and Se at 106 cycles by a straight line on an S.N. graph
(b) Joining the 0.9 Sut at 1000 cycles and Se at 106 cycles by a straight line on a log
[IES 2007]
S- log N graph
(c) Joining the 0.9 Sut at 1000 cycles and Se at 106 cycles by a straight line on an S-N
graph
(d) Joining the Sut at 1000 cycles and 0.9 Se at 106 cycles by a straight line on a log
S- log N graph
(Sut stands for ultimate tensile strength and Se for the endurance limit)
IES 2. Ans. (b)
IES 3.
Endurance Limit
S K Mondals
Chapter 5
IES 4.
Match List I with List II and select the correct answer using the codes
given below the lists:
[IES-1993]
List I (Material properties) List II(Tests to determine material properties)
A. Ductility
1. Impact test
B. Toughness
2. Fatigue test
C. Endurance limit
3. Tension test
D. Resistance to penetration
4. Hardness test
Code:
A
B
C
D
A
B
C
D
(a)
3
2
1
4
(b)
4
2
1
3
(c)
3
1
2
4
(d)
4
1
2
3
IES 4. Ans. (c)
When and Young's Modulus of Elasticity E remain constant, the energyabsorbing capacity of part subject to dynamic forces, is a function of its
[IES-1992]
(a) Length
(b) cross-section
(c) volume
(d) none of the above
IES 5. Ans. (c) Strain energy is given by,
2
U = A.L.
2E
Where and E remaining constant,
U is proportional to (A.L.) which is volume.
Also, since U is a function of 2 , that portion of the part which is prone to high
localised will absorb a high amount of energy, making it vulnerable to failure. Such
a part, therefore, is designed to have such a contour that, when it is subjected to
time-varying or impact loads or others types of dynamic forces, the part absorbs or
less uniform stress distribution along the whole length of the part is ensured.
IES 5.
IES 6.
Fatigue strength of a rod subjected to cyclic axial force is less than that of
a rotating beam of the same dimensions subjected to steady lateral force.
What is the reason?
[IES-2009]
(a) Axial stiffness is less than bending stiffness
(b) Absence of centrifugal effects in the rod
(c) The number of discontinuities vulnerable to fatigue is more in the rod
(d) At a particular time, the rod has only one type of stress whereas the beam has
both tensile and compressive stresses
IES 6. Ans. (d)
The design calculations for members subject to fluctuating loads with the
same factor of safety yield the most conservative estimates when using
S K Mondals
Chapter 5
(b) Soderberg relation [IES-1995]
(d) none of the above.
IES 9.
Gyroscopic motion
IES 10.
Assertion (A): The precession of the axis of rotation of a shaft causes a gyroscopic
reaction couple to act on the frame to which the bearings are fixed.
Reason (R): The reaction of the shaft on each bearing is equal and opposite to the
[IES-2002]
action of the bearing on the shaft.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES 11. Ans. (b)
IES 12.
Assertion (A): There is a danger of locomotive wheels being lifted above rails at
[IES-2001]
certain speeds.
Reason (R): Lifting of the locomotive wheel above rails at certain speed is due to
gyroscopic action.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IES 12. Ans. (c)
S K Mondals
Chapter 5
60
IAS 2.
[IAS 1994]
IAS 3.
a
b
a
b
2b
(c) Kt =1+
a
2a
(d) Kt = 1+
b
(b) Kt =1+
[IAS-1998]
Assertion (A): Endurance limits for all materials are always less than the ultimate
[IAS 1994]
strength of the corresponding materials.
Reason (R): Stress concentration in a machine part due to any dislocation is very
damaging when the part is subjected to variable loading.
(a) Both A and R are individually true and R is the correct explanation of A
(b) Both A and R are individually true but R is not the correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
IAS 4. Ans. (b)
IAS 5.
S K Mondals
(c) 2
IAS 5. Ans. (b)
Chapter 5
3
(d)
IAS 6.
Miscellaneous
S K Mondals
6.
Chapter 6
Miscellaneous
Theory at a glance (GATE, IES, IAS & PSU)
Fracture
Fracture defined as the separation or fragmentation of a solid body into two or more
parts under the action of stress.
Fracture is classified based on several characteristic features:
characteristic
Strain to fracture
Crystallographic mode
Appearance
Crack propagation
terms used
Ductile
Brittle
Shear
Cleavage
Fibrous and gray
Granular and bright
Along grain boundaries
Through grains
Fracture modes
Ductile fracture
Higher
Increasing
Slow
Plastic deformation
Extensive
Yes
Rough and dull
Brittle fracture
Lower
Constant
Fast
None
Little
No
Smooth and bright
Miscellaneous
S K Mondals
Chapter 6
D Type of materials
Ductile fracture
f =
(1 n ) ln (l0 / 2b0 )
sinh (1 n )( a + b ) / ( 2 /
Stages of void nucleation, void growth, crack initiation and eventual fracture under
ductile fracture mode:
Brittle fracture
Nominal fracture stress that causes brittle fracture in presence of cracks (length of
interior crack=2c), the stress raisers,
Mis
scellan
neous
S K Monda
M
als
Chapte
er 6
1/2
E
f
4c
c
1/2
2E
Wh
hen plastic energy
e
is alsso taken intto account (O
Orowans modification)
m
):
2E ( + p)
=
1/2
1/2
Ep
Fractu
ure mec
chanics
s
Rellatively new
w field of mechanics, th
hat deals with
w
possibillity whetherr a crack off given
len
ngth in a ma
aterial with known toug
ghness is da
angerous at a given streess level or not!
Fra
acture resisstance of a material in the prresence of cracks, kn
nown as fra
acture
tou
ughness, is expressed
e
in
n two forms.
2c
(1) Strain-enerrgy release rate, (G): G =
E
(2) Stress conccentration fa
actor, (K): K = c
Botth paramete
ers are relatted as:
Forr plane stress condition
ns i.e. thin p
plates: K 2 = GE
K depends
d
on many factors, the most influentia
al of which are
a tempera
ature, strain
n rate,
miccrostructuree and orien
ntation of frracture. Thee value of K decreasess with increeasing
stra
ain rate, gra
ain size and
d/or decreasing tempera
ature.
Dep
pending on
n the orienttation of fracture, thre
ee modes oof fracture are identifi
fied as
shoown in the figure:
f
Misc
cellane
eous
S K Mo
ondals
C
Chapter
r6
DuctileD
to-Britttle transition
Energ
gy absorbed
d during thee notch-imp
pact is plotted as a fu
unction of temperaturee to
know at what tem
mperature range
r
(DBTT
T) material fracture in a particular mode.
In
n metals DBTT is aroound 0.1-0.2
2 Tm while in ceramiccs it is aboout 0.5-0.7 Tm, where Tm
re
epresents ab
bsolute meltting temperrature.
Fatigue
F
failure
Miscellaneous
S K Mondals
Chapter 6
Stress cycles that can cause fatigue failure are characterized using the following
parameters:
a = r 2 = (max min 2)
Mean stress,
m = (max + min 2)
Stress ratio,
Amplitude ratio,
R = min max
A= a m = (1-R)(1+R)
Material fails under fatigue mode at higher number of stress cycles if stress applied is
lower.
After a limiting stress, ferrous materials wont fail for any number of stress cycles. This
limiting stress is called fatigue limit / endurance limit.
For non-ferrous materials, there is no particular limiting stress i.e. as stress reduces,
number of cycles to failure keep increasing. Hence stress corresponding to 107 cycles is
considered as characteristic of material, and known as fatigue strength. Number of
cycles is called fatigue life.
Endurance ratio ratio of fatigue stress to tensile stress of a material. For most
materials it is in the range of 0.4-0.5.
Fatigue failure consists of four stages: (a) crack initiation includes the early
development of fatigue damage that can be removed by suitable thermal anneal (b) slipband crack growth involves the deepening of initial crack on planes of high shear
stress (stage-I crack growth) (c) crack growth on planes of high tensile stress involves
growth of crack in direction normal to maximum tensile stress (stage-II crack growth)
(d) final ductile failure occurs when the crack reaches a size so that the remaining
cross-section cannot support the applied load.
Stage-I is secondary to stage-II crack growth in importance because very low crack
propagation rates involved during the stage.
Misc
cellane
eous
S K Mo
ondals
C
Chapter
r6
Fatigue
F
crack growth
g
h: Stage
e-I Vs Stage-II
S
Fatigue
F
crack propag
p
gation rrate
Studie
es of fatiguee crack prop
pagation ratte attained much
m
imporrtance becau
use it can bee
used as
a fail-safe design
d
consiideration.
da
= fn ( ,a ) = Cama n
dN
Pariss law:
da
p
= A ( K )
dN
p = 3 for
f steels, 3-4
4 for A1 alloys
Creep
C
fa
ailure
Deform
mation thatt occurs und
der constantt load/stresss and elevatted tempera
atures which
h is
time-d
dependent is known as creep.
Creep
p deformatio
on (constantt stress) is p
possible at all
a temperattures abovee absolute zeero.
Howev
ver, it is exttremely sen
nsitive to tem
mperature.
Hencee, creep in usually
u
considered imp
portant at elevated
e
tem
mperatures (temperatu
ures
greate
er than 0.4 Tm
T , Tm is absolute
a
meelting tempe
erature).
Creep
p test data iss presented as a plot beetween timee and strain
n known as creep
c
curve..
The sllope of the creep
c
curve is designateed as creep rate.
Mis
scellan
neous
S K Monda
M
als
Chapte
er 6
Andrade creep
p equation:
k
= 0 1 + t1/3 ekt
Garrofalo creep
p equation:
= 0 + t 1 e rtt + st
Tw
wo most impo
ortant para
ameter that influence crreep rate arre: stress an
nd temperature.
Witth increase in either stress or temperature (a)) instantaneeous elastic strain increeases
(b) steady statte creep ratee increases a
and (c) ruptture lifetimee decreases..
Misc
cellane
eous
S K Mo
ondals
s = K 2 e
C
Chapter
r6
Qc
RT
R
Dynamo
D
ometers
s
Foor consisteently accurrate and reliable
r
meeasurementt, the folloowing requ
uirements are
co
onsidered du
uring design
n and constrruction of any tool forcee dynamom
meters:
Sensiitivity : the
e dynamom
meter shou
uld be reeasonably sensitive for precission
me
easurement
Rigid
dity : the
e dynamomeeter need too be quite rigid
r
to with
hstand the forces with
hout
causiing much deeflection wh
hich may afffect the macchining cond
dition
Crosss
Sensiitivity: the
e dynamomeeter should be free from
m cross senssitivity such
h that one foorce
(say PZ) does not
n affect meeasurementt of the otheer forces (say PX and PY)
Constru
C
uction and
a working p
principle
e of some com
mmon
to
ool fo
orce dy
ynamom
meters.
Th
he dynamo
ometers be
eing commoonly used now-a-dayss for meassuring macchining forrces
deesirably acccurately and
d precisely (b
both static and dynamiic characterristics) are
Either strain gaugee type
Or piezoelectric type
Sttrain gaugee type dynamometers are
a inexpen
nsive but lesss accurate and consisstent, whereeas,
th
he piezoelecctric type arre highly acccurate, reliiable and co
onsistent bu
ut very expe
ensive for high
h
material
m
costt and stringe
ent construction.
Measuri
M
ing Horrsepow
wer
Sh
hows the prrony brake or
o dynamom
meter methood of measu
uring motor horsepowerr. This meth
hod
is valid for alll types of motors
m
inclu
uding intern
nal combustiion engines, turbines, and
a all electric
motors.
m
Mis
scellan
neous
S K Monda
M
als
Chapte
er 6
Fig. Pron
ny-brake dynamometerr.
TQ = 24 25
2 = 600 lb in or 50lb ft
From this
TR =
5250 ( hp )
Nr
hp =
50 ( 250 )
TR N r
=
= 2.38
8hp
52
5250
250
where hp
p = horsepoower (1 hp = 33,000ft lb
b / min = 55
50ft lb / sec ) .
TR = running
g torque, lb ft
N r = running
g speed, rpm
m
Brak
ke
1. Typ
pes of brakes
b
Brakes arre devices that dissip
pate kineticc energy off the moving parts of
o a machin
ne. In
mechanica
al brakes th
he dissipatiion is achieeved throug
gh sliding frriction betw
ween a statiionary
object and
d a rotating
g part. Depeending upon
n the directtion of appllication of braking
b
forcce, the
mechanica
al brakes arre primarily
y of three typ
pes
2. Sho
oe or block bra
ake
In a shoe brake the rotating
r
dru
um is broug
ght in conta
act with thee shoe by su
uitable forcee. The
contacting
g surface of the shoe iss coated witth friction material.
m
Diifferent types of shoe brakes
b
are used, viz., single shoe bra
ake, double shoe brak
ke, internal expanding
g brake, ex
xternal
expanding
g brake. Theese are sketched in figu
ure below
Misc
cellane
eous
S K Mo
ondals
Chapter
C
r6
Mis
scellan
neous
S K Monda
M
als
Chapte
er 6
Single
e Shoe brake
The force needed
n
to secure conta
act is supplied by a leveer. When a fforce F is ap
pplied to the shoe
(see figuree below) fricctional forcee proportion
nal to the ap
pplied force Ffr = ' F develops,
d
wh
here '
depends of
o friction material
m
and
d the geometry of the shoe. A sim
mplified an
nalysis is doone as
discussed below.
Figure
e Free body diagram off a brake shooe
Though th
he exact nature of the contact presssure distrib
bution is unk
known, an approximati
a
ion
(based on wear consid
derations) iss made as
p ( ) = p0cos
Where the
e angle is measured from the centeerline of thee shoe. If Coulombs law
w of friction is
assumed to
t hold good
d, then
ffr ( ) = p0cos
Since the net
n normal force of the drum is F, one has
0
Rb p ( ) cosd = F,
0
Where R and
a b are th
he radius of the brake d
drum and wiidth of the sshoe respecttively.
Miscellaneous
S K Mondals
Chapter 6
T = b ffr ( ) R 2d
0
Miscellaneous
S K Mondals
Chapter 6
equilibrium. Without any force the shoe will, in this case, draw the lever closer to the drum by
itself. This kind of brake is known as self-locking, brake. Two points deserve attention.
(1) If a < 0, the drum brake with clockwise rotation becomes self-energizing and if friction is
large, may is self locking.
(2) If the brake is self locking for one direction, it is never self locking for the opposite
direction. This makes the self locking brakes useful for back stops of the rotors.
Miscellaneous
S K Mondals
Chapter 6
joining the pivot and the center of the drum and the line joining the center and the chosen
point. This means
p ( ) = p0 sin ,
Mp = p0 bR ( 2 1 ) + ( sin 21 sin 22 ) ,
2
2
Mf =
0 bR R ( cos 1 2 ) ( cos 21 22 ) ,
2
4
Where is the distance between the center and the pivot (OO1 in figure below) and is the
distance from the pivot to the line of action of the force F1 (O1C in the figure). In a similar
manner the force to be applied at the other shoe can be obtained from the equation
F2 l =Mp +Mf
The net braking torque in this case is
T = p0 bR 2 ( cos1 -cos2 ) .
Mis
scellan
neous
S K Monda
M
als
Chapte
er 6
1. Ban
nd brakes
The operating princip
ple of this ty
ype of brakee is the folloowing. A fleexible band of leather or
o rope
or steel with
w
friction
n lining is wound rou
und a drum
m. Frictional torque is generated when
tension is applied to the band. It is known (see any tex
xt book on engineering
g mechanicss) that
the tension
ns in the tw
wo ends of th
he band aree unequal beecause of friction and bear
b
the folllowing
relationsh
hip:
T1
= e ,
T2
Where T1 = tension in
n the taut siide,
n the slack side,
s
T2 = tension in
= coefficient of kinetic friction and
d
= angle of wrap.
w
If the band
d is wound around
a
a drrum of radiu
us R, then th
he braking torque is
Tbr = ( T1 T2 ) R = T1 1 e R
Depending
g upon the connection
c
o the band to the leverr arm, the member
of
m
resp
ponsible for
application
n of the tensions, the band brakes are of two types,
t
(a) Simplle band bra
ake:
In simple band brake one end of
o the band
d is attache
ed to the fu
ulcrum of th
he lever arm
m (see
figures bellow). The re
equired force to be appllied to the leever is:
b
= for clockwiise rotation of the brak
ke drum and
d
l
b
P = T2 = for anticlocckwise rotattion of the b
brake drum,,
l
P = T1
Where l = length of th
he lever arm
m and
b = perpendicular distance from
m the fulcru
um to the point
p
of atta
achment of other end of the
band.
(b) Differ
rential ban
nd brake:
Miscellaneous
S K Mondals
Chapter 6
In this type of band brake, two ends of the band are attached to two points on the lever arm
other than fulcrum (see figures above). Drawing the free body diagram of the lever arm and
taking moment about the fulcrum it is found that
a
a
T1 , for clockwise rotation of the brake drum and
l
l
a
a
P = T1 T2 , For anticlockwise rotation of the brake drum.
l
l
P = T2
Hence, P is negative if
T a
e = 1 > For clockwise rotation of the brake drum
T2 b
T1 a
< for counterclockwise rotation of the brake drum. In these cases the force is
T2 b
to be applied on the lever arm in opposite direction to maintain equilibrium. The brakes are
then self locking.
And
e =
The important design variables of a band brake are the thickness and width of the band. Since
the band is likely to fail in tension, the following:
Relationship is to be satisfied for safe operation.
T1 = wts T
Where
w
t
25-40 mm
3 mm
40-60 mm
3-4 mm
80 mm
4-6 mm
100 mm
4-7 mm
140-200 mm
6-10 mm
Mis
scellan
neous
S K Monda
M
als
Chapte
er 6
2. Ban
nd and block
b
b
brakes
Sometimes instead of
o applying continuous friction lin
ning along tthe band, blocks
b
of woood or
other fricttional mate
erials are inserted
i
bettween the band and the drum. In this casse the
tensions within
w
the ba
and at both sides of a b
block bear th
he relation
T1 1 + tan
=
,
T1 1 tan
Where T1 = tension at the taut siide of any block
a the slack side of the ssame block
T1 = tension at
2 = angle sub
btended by each block at
a center.
If n numbe
er of blocks are used th
hen the ratioo between th
he tensions at taut sidee to slack siide
becomes
T1 1 + tan
=
T2 1 tan
The brakin
ng torque iss
Tbr = ( T1 T2 ) R
c brake
e
3. Disc
In this typ
pe of brake two friction
n pads are pressed
p
axiially againstt a rotating
g disc to disssipate
kinetic ene
ergy. The working
w
prin
nciple is verry similar to
o friction clu
utch. When the pads arre new
the pressu
ure distributtion at pad-disc interfa
ace is uniform
m, i.e.
P = constant.
F
, where A is the area
If F is the total axial force
f
applie
ed then p =
a of the pad.
A
The frictio
onal torque is given by
Miscellaneous
S K Mondals
Chapter 6
Tbraking =
F
A
rdA
where = coefficient of kinetic friction and r is the radial distance of an infinitesimal element
of pad. After some time the pad gradually wears away. The wear becomes uniforms after
sufficiently long time, when
pr = constant = c (say)
where
F=
dA
. The braking torque is
r
AF
Tbraking ' = prdA = Ac =
dA
r
pdA = c
It is clear that the total braking torque depends on the geometry of the pad. If the annular pad
is used then
2 R13 R32
Tbr = F 2
3 R1 R 22
R + R2
T'br = F 1
Where R1 and R 2 are the inner and outer radius of the pad.
Some common friction materials are woven cotton lining, woven asbestos lining, molded
asbestos lining, molded asbestos pad, Sintered metal pads etc.
Miscellaneous
S K Mondals
Chapter 6
brake lining and the drum is 0.4, find the spring force necessary to transmit a
torque of 30 Nm. Also determine the width of the brake shoe if the braking pressure
on the lining material is not to exceed 0.28 MPa.
'
'
20 + sin 20
4
writing the moment equilibrium equations about the pivot points of individual shoes (draw
correct FBDs and verify)
Sl
Sl + N1x + F1a = 0 F1 =
= 0.718S, and
x
a+
'
Sl
= 1.1314S
Sl + N 2 x + F2a = 0 F2 =
x
a
'
This yields S = 98.4(N).
ANSWER The design of belt is to be carried out when the braking torque is maximum i.e. Tbr =
1000 N-m. According to the principle of band brake
4
0.3
3
Tbr = T1 1 e R = T1 1 e
0.25
Which yield T1 = 5587N, T2 = e T1 = 1587N. In order to find the pressure on the band,
consider an infinitesimal element. The force balance along the radial direction yields
N = T
Since N = pbR so p =
T
.
bR
b=
T1
.
bR
5587
= 0.112m ( approx.)
0.25 0.2 106
Which yields t =
5587
= 0.0007145 m or 1 mm ( approx.) .
70 106 0.1117
Misc
cellane
eous
S K Mo
ondals
C
Chapter
r6
Object
O
ive Qu
uestion
ns (For GATE
E, IES & IAS
S)
Prev
vious 20-Yrs
2
GATE
E Ques
stions
GATE-1.
G
In
n a 2-D CAD
D package, clockwise
e circular arc of radius 5, spec
cified from
m P1
(15
5, 10) to P2(10, 15) wiill have its center at
[GATE-200
04]
(d) (10, 15
(a)) (10, 10)
(b) (15, 10)
(c) (15, 15)
1
5)
GATE-1.
G
An
ns. (c)
Giv
ven: P1 (15,10)
P2 (10,15)
Clearly from fiigure,
Cen
ntre of are having
h
radiu
us
= 5 is (15, 15)
GATE-2.
G
A band brak
ke having
g band-wid
dth of 80 mm,
m
drum
m diameter
r of 250 mm,
m
co
oefficient of
o friction of 0.25 and angle off wrap of 2
270 degree
es is requir
red
to exert a friction
f
to
orque of 1000
1
N m. The max
ximum ten
nsion (in kN)
k
de
eveloped in
n the band
d is
[GATE-201
10]
(d) 11.56
(a)) 1.88
(b) 3.56
6
(c) 6.12
GATE-2.
G
An
ns. (d)
f Linked Answer GATEG
3 and
d GATE-4:
Sttatement for
A band brake con
nsists of a lever
attached to one end of the ba
and. The
other end of
o the ban
nd is fixed to the
gr
round. The
e wheel has a radiu
us of 200
mm
m and the
e wrap an
ngle of the
e band is
27
70o. The braking for
rce applie
ed to the
lev
ver is lim
mited to 100 N, and the
co
oefficient of
o friction between tthe band
an
nd the wheel is 0.5. No
o other
information is given.
GATE-3.
G
Th
he maximu
um tension
n that can b
be generatted in the b
band durin
ng braking
g is
[G
GATE-2005]]
0N
(c) 3224
4N
(d) 4420 N
(a)) 1200 N
(b) 2110
GATE-3.
G
An
ns. (b)
Ta
aking momeent about hinge
T2 1 = 100 2
T1
= e ,
T2
w
where
3
2
GATE-4.
G
Th
he maximu
um wheel torque
t
thatt can be co
ompletely b
braked is [GATE-200
05]
(a)) 200 N.m
(b) 382 N.m
(c) 604 N.m
N
(d) 844 N..m
GATE-4.
G
An
ns. (b)
Mis
scellan
neous
S K Monda
M
als
Chapte
er 6
GATE-5. In a band
d brake the
e ratio of tight
t
side band tenssion to the
e tension on
o the
slack side
e is 3. If the
t
angle of overlap
p of band on the dr
rum is 180
0 the
coefficien
nt of frictio
on required
d between drum and
d the band is [GATE--2003]
(a) 0.20
(b) 0.25
0
(c) 0.3
30
(d) 0.35
5
GATE-5. Ans.
A
(d)
GATE-6. A block-b
brake show
wn below h
has a face
e width off 300 mm and
a
a mea
an coefficient of
o friction of 0.25. F
For an actiivating for
rce of 400 N, the bra
aking
torque in Nm is
[GATE-2
2007]
(a) 30
GATE-6. Ans.
A
(c)
(b) 40
4
(c) 45
(d) 60
Prrevious 20-Y
Yrs IES
S Ques
stions
IES-1.
What is th
he correct sequence o
of the follo
owing step
ps in engine analysis??
1. Vibratio
on analysis
2. Ine
ertia force analysis.
[IES--1997]
3. Balanciing analysiis
4. Vellocity and Acceleration analyssis.
Select the
e correct an
nswer usin
ng the code
es given be
elow:
(d) 4, 2,
(a) 2, 4, 1, 3
(b) 2,
2 4, 3, 1
(c) 4, 2, 1, 3
2 3, 1
IES-1. An
ns. (c)
A device for
f
lifting or lowerin
ng objects suspended from a hook
h
at the end
1995]
of a retrac
ctable chain or cable
e is called
[IES-1994;
[
(a) Hoist
(b) jiib crane
(c) cha
ain conveyoor
(d) elev
vator
ns. (a)
IES-2. An
IES-2.
IES-4.
Miscellaneous
S K Mondals
Chapter 6
1. The speed of the crown wheel will always be the mean of the speeds of
the two road wheels.
2. The road wheel speeds are independent of the number of teeth on the
planets.
3. The difference between the speeds of the road wheels depends on the
number of teeth on the planets.
4. The ratio of speeds of the road wheels depends upon the number of teeth
on the gear wheels attached to them and on the crown wheel.
Of these statements
(a) 1 and 2 are correct
(b) 3 and 4 are correct
(c) 1 and 3 are correct
(d) 2 and 4 are correct.
IES-4. Ans. (d)
IES-5.
[IES-1993]
IES-6.
Which of the following stresses are associated with the tightening of a nut
on a stud?
1. Tensile stresses due to stretching of stud.
2. Bending stresses of stud.
[IES-1993]
3. Transverse shear stresses across threads.
4. Torsional shear stresses in threads due to frictional resistance.
Select the correct answer using the codes given below:
(a) 1, 2 and 3
(b) 1, 2 and 4
(c) 2, 3 and 4
(d) 1, 3 and 4
IES-7. Ans. (a)
IES-8.
[IES-1992]
List II (Characteristics)
1. High speeds and low power
2. Power absorbed independent of
size of flywheel.
3. Power absorbed available for
useful applications
4. Large powers
[IAS-2001]
Miscellaneous
S K Mondals
(a) Water as lubricant
(c) Grease as lubricant
IAS-1. Ans. (d)
Chapter 6
(b) oil as lubricant
(d) no lubricant
IAS-2.