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DIPLOMA ENGINEERING
DEPARTMENT OF MECHANICAL
ENGINEERING
LAB MANUAL
SUBJECT: THEORY OF MACHINES.
(3341903)
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
1 PREPERATORY ACTIVITY
4 TO STUDY CLUTCH
TO STUDY OF VARIOUS
5 MECHANICAL POWER
TRANSMISSION SYSTEMS
TO STUDY OF BALANCING
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TO STUDY ABOUT
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FLYWHEEL AND FUCTION
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
EXPERIMENT NO. 1
INTRODUCTION ABOUT UNITS AND MICHANISM
SUPPLEMENTARY UNITS:
QUANTITY NAME SYMBOL
Plane angle Radian Rad
Solid angle steradian Sr
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
1. FORCE
1 newton = 1 kg m/sec = 0.012 kgf
1 kgf = 9.81 N
2. PRESSURE
1 bar = 750.06 mm Hg = 0.9869 atm = 10 N/m = 103 kg/m sec
1 N/m = 1 pascal = 10 bar = 10 kg/ sec = 1001325 * 10 N/m
3. POWER
1 watt = 1 joule/sec
1 h.p = 735.5 watt
1 KW = 1000 watts.
Scalars are quantities that are fully described by a magnitude (or numerical value) alone.
Example: Mass, Distance, Speed, Temperature etc.
Vectors are quantities that are fully described by both a magnitude and a direction.
Example: Velocity, Acceleration etc.
ADDITION AND SUBTRACTION OF TWO VECTORS
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
EXPERIMENT NO. 2
VELOCITY AND ACCELERATION
Introduction
Kinematics deals with study of relative motion between the various parts of the machines.
Kinematics does not involve study of forces. Thus motion leads study of displacement, velocity
and acceleration of a part of the machine. Study of Motions of various parts of a machine is
important for determining their velocities and accelerations at different moments.
As dynamic forces are a function of acceleration and acceleration is a function of
velocities, study of velocity and acceleration will be useful in the design of mechanism of a
machine. The mechanism will be represented by a line diagram which is known as configuration
diagram. The analysis can be carried out both by graphical method as well as analytical method.
Displacement: All particles of a body move in parallel planes and travel by same
distance is known, linear displacement and is denoted by ‘x’. A body rotating about a fired point
in such a way that all particular move in circular path angular displacement and is denoted by‘θ’.
Absolute velocity: Velocity of a point with respect to a fixed point (zero velocity point).
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
Acceleration Analysis:
Rate of change of velocity is acceleration. A change in velocity requires any one of the
following conditions to be fulfilled:
Change in magnitude only
Change in direction only
Change in both magnitude and direction
When the velocity of a particle changes in magnitude and direction it has two component of
acceleration.
1. Radial or centripetal acceleration
fc = ω2r
Acceleration is parallel to the link and acting towards center.
2. Tangential Acceleration:
ft = αBA acts ⊥ to link
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
1. In a four bar chain ABCD, AD is fixed link. Crank AB rotates in clock wise direction at
an angular velocity of 10 rad /sec. Link AB=60 mm, BC=CD =70 mm, DA =120 mm.
When angle DAB = 60 degree and points B and D on one side of the link AD, find
angular velocity of link BC and CD.
3. In an I.C.Engine the length of the crank and connecting rod are 0.2m and 0.8m
respectively. The crank rotates uniformly at 420 rpm in clockwise direction. The crank
has turned to 30o from I.D.C. Determine the followings by relative velocity method.
(i) Velocity of piston
(ii) Acceleration of piston.
4. The stroke of a reciprocating steam engine is 360 mm and length of the connecting is 600
mm. The crank rotates at uniform speed of 300 r.p.m. in clock wise direction. For the
crank position of 210 degree from I.D.C. determine using Relative velocity approach the
following:
i. Velocity and acceleration of piston.
ii. Angular velocity and angular acceleration of the connecting rod.
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
EXPERIMENT NO. 3
CAM AND CAM PROFILE
INTRODUCTION
A cam is a mechanical device used to transmit motion to a follower by direct contact. The
driver is called the cam and the driven member is called the follower. In a cam follower
pair, the cam normally rotates while the follower may translate or oscillate. A familiar
example is the camshaft of an automobile engine, where the cams drive the push rods (the
followers) to open and close the valves in synchronization with the motion of the pistons.
Cam Nomenclatures:
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
Classification of Follower.
1. According to the surface in contact. The followers, according to the surface in contact, are as
follows:
When the contacting end of the follower has a sharp knife edge, it is called a knife edge
follower, as shown in Fig. 20.1 (a). The sliding motion takes place between the contacting
surfaces (i.e. the knife edge and the cam surface). It is seldom used in practice because the small
area of contacting surface results in excessive wear. In knife edge followers, a considerable side
thrust exists between the follower and the guide.
(b) Roller follower:-
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
When the contacting end of the follower is a roller, it is called a roller follower, as
shown in Fig. Since the rolling motion takes place between the contacting surfaces (i.e. the
roller and the cam), therefore the rate of wear is greatly reduced. In roller followers also the
side thrust exists between the follower and the guide. The roller followers are extensively
used where more space is available such as in stationary gas and oil engines and aircraft
engines.
When the contacting end of the follower is a perfectly flat face, it is called a flat-faced follower,
as shown in Fig. 20.1 (c). It may be noted that the side thrust between the follower and the
guide is much reduced in case of flat faced followers. The only side thrust is due to friction
between the contact surfaces of the follower and the cam. The relative motion between these
surfaces is largely of sliding nature but wear may be reduced by off-setting the axis of the
follower, as shown in Fig. 20.1 (f ) so that when the cam rotates, the follower also rotates
about its own axis. The flat faced followers are generally used where space is limited
such as in cams which operate the valves of automobile engines.
(d) Spherical faced follower.
When the contacting end of the follower is of spherical shape, it is called a spherical faced
follower, as shown in Fig. It may be noted that when a flat-faced follower is used in automobile
engines, high surface stresses are produced. In order to minimize these stresses, the flat end
of the follower is machined to a spherical shape.
2. According to the motion of Follower two types:
(a) Reciprocating or translating follower.
When the follower reciprocates in guides as the cam rotates uniformly, it is known as
reciprocating or translating follower.
When the uniform rotary motion of the cam is converted into predetermined oscillatory motion
of the follower, it is called oscillating or rotating follower.
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
The followers, according to its path of motion, are of the following two types:
When the motion of the follower is along an axis passing through the centre of the cam, it is
known as radial follower.
When the motion of the follower is along an axis away from the axis of the cam centre, it is called off-
set follower.
Questions.
1. Draw the cam Profile to reciprocate the knife edge follower from the following details.
(1) Out stroke of follower is with S.H.M. for 120◦ rotation of cam. Lift of follower =
42mm.
(2) Follower remains lifted during next 60◦ rotation of cam.
(3) Follower moves inward with uniform velocity during 90◦ of cam rotation.
(4) For remaining period of cam rotation, the follower remains at the bottom.
(5) Least Radius of cam is 30 mm and cam rotates in clockwise direction.
2. Draw cam profile for a cam operating a pivoted follower from the following data (a) the
follower moves out ward with S.H.M. during 120° rotation of cam. (b) The follower
remains lifted during 90° rotation of cam. (c) The follower moves inward with uniform
velocity during 120° rotation of cam. (d) The follower remains at the bottom for the rest
of rotation.(e) stroke of follower =42 mm. (f) least radius of cam =35 mm (g) the
follower is radial and the cam shaft rotates in anticlockwise direction.
3. Draw cam profile to move the roller follower to give 30mm lift with S.H.M. during 120
degree of cam rotation and it dwell for 30 degree of cam rotation then it returns with
uniform acceleration and retardation during 150 degree rotation. The follower remains in
rest at remaining period. The axis of follower passes through the axis of cam shaft. The
cam rotates in anticlockwise direction. The base circle diameter of the cam is 50 mm.
4. Draw the cam Profile to the knife edge follower from the following details.
(1) Out stroke of follower is with uniform velocity for 60◦ rotation of cam. Lift of
follower = 42mm.
(2) Follower remains lifted during next 30◦ rotation of cam.
(3) Follower moves inward with uniform velocity during 60◦ of cam rotation.
(4) For remaining period of cam rotation, the follower remains at the bottom.
(5) Least Radius of cam is 30 mm and the axis of follower is 15 mm offset from the
shaft. Cam rotates in clockwise direction.
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
Marks obtained: Signature of faculty: Date:
EXPERIMENT NO. 4
CLUTCHES
Single Plate Clutch: A single disc or plate clutch consists of a clutch plate whose both sides are faced with a
frictional material. It is mounted on the hub which is free to move axially along the splines of the driven shaft.
The pressure plate is mounted inside the clutch body which is bolted to the flywheel. Both the pressure plate
and the flywheel rotate with the engine crank shaft or the driving shaft. The pressure plate pushes the clutch
plate towards the flywheel by a set of strong springs which are arranged radially inside the body.
The three levers (also known as release levers or fingers) are carried on pivots suspended from the case of the
body. These are arranged in such a manner so that the pressure plate moves away from the flywheel by the
inward movement of a trust bearing. The bearing is mounted upon a forked shaft and moves forward when the
clutch pedal is pressed
When the clutch pedal is pressed down, its linkage forces the thrust release bearing to move in towards the
flywheel and pressing the longer ends of the levers inward.
The axial pressure exerted by the spring provides a frictional force in the circumferential direction when the
relative motion between the driving and driven members tends to take place. If the torque due to this frictional
force exceeds the torque to be transmitted, then no slipping takes place and the power is transmitted from the
driving shaft to the driven shaft.
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
EXPERIMENT NO. 5
POWER TRANSMISSION SYSTEM
INTRODUCTION:-
The belts or ropes are used to transmit power from one shaft to another by means of pulleys which
rotate at the same speed or at different speeds. The amount of power transmitted depends upon the
following factors:
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
iii-Circular belt or rope belt:-
The circular belt or rope, as shown in Fig. 11.1 (c), is mostly used in the factories and workshops, where a
great amount of power is to be transmitted, from one pulley to another, when the two pulleys are more than
8 meters apart.
Types of Belt
Compare between flat and v-belt:-
Flat belt:-The belt are known as flat belt as the shape of cross section of the belt is flat rectangular. Flat belt
is mostly used in workshop, industrial equipment’s where moderate amount of power is to be transmitted.
The maximum center distance for single drive is limited to about 8 meters. Material used for flat belt are
leather, cotton ,fabric ,rubber ,synthetic material etc.
V-belt :-Cross section of this type of belt is trapezoid or a V-shape, cut from bottom side and hence it is
known as ‘V’ belt. It is the most suitable drive for having relatively short center distance between the axes
of driving and driven shaft. Using more than one belt large power can be transmitted. Material used for V-
belt are fabric, vulcanized rubber with cotton, rubber impinged fabric with angle between 30 to 40
(8) Design of pulley for V belt is slightely complex compare to flat belt.
(9) When more number of v belt are used matched sets are to be used.
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
Slip of belt drive is the firm frictional grip between the belt and pulley causes the movement of the belt on
the pulley without slipping. If the frictional grip is in-sufficient, some forward motion of pulley will take
place without carrying the belt with them. This is known as slip of belt. Thus the difference between the
linear speed of the rim of the pulley and belt on it is known as slip of the belt drive.
The result of the belt slipping is to reduce the velocity ratio of the system. As the slipping of the belt is a
common phenomenon, thus the belt should never be used where a definite velocity ratio is importance
TYPES OF BELT DRIVES:-
(1) Belt drive- Belt drive is formed by connecting two pulleys through endless belt.
(2) Rope drive- When the center distance between driver and driven shaft is very large and high power is
required to be transmitted, is such cases rope drive are used.
(3) Open belt drive- In such drive the driving and the driven shafts are parallel to each other and they
rotate in same direction.
(4) Crossed belt drive- In crossed belt drive the driven pulley rotates in the opposite direction to that of
driven pulley.
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
(5) Compound belt drive- The compound belt drive is used when the distance between input and output
shaft is large and also when the high velocity is required.
Train-value: In any given gear drive the ratio of the driven or follower to the speed of the driven is known
as train value of the gear train.
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
Such gear train are used in mechanical clocks where minute and hour hand are attached to the gear in the
same axis, in automobile gear box, in back gear of lathe etc.
Gear 1 is mounted on driving shaft and drives the gear 4 through compound gear 2 and 3while the axis of
the driving and the driven shaft coincide. Such gear are compact and provide high speed ratio.
Epi-cyclic Gear Train:
In simple gear train and compound gear train the axes of the shaft are fixed. Where as in the epi-cyclic gear
train the axes of the shaft on which the gear train are mounted may have the relative motion between them.
Gear A and arm C have common axis O1 about which they can rotate gear B meshes with gear A and has
its axis o2 and can also revolves along with the arm about the axis o1. When the arm Is fixed the gear train
where gear A or gear B or vice versa. But if gear A is fixed and the arm C is rotate about the axis of gear A
than the gear B is forced to rotate upon and around gear A. such motion is called epicycle
and the gear train arranged in such a manner is known as epicycle gear train. Epicycle gear train may
consist of simple, compound or reverted gear train. Epicycle gear train are also known as planetary gear
train as the motion of the gear are like sun and planet.
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
This is the simplest type of gear box. The figure gives a simplified view if the gear box. The power comes
from the engine to the clutch shaft and hence to the clutch gear which is always in mesh with a gear on
the lay shaft. All the gears on the lay shaft are fixed to it and as such they are all the time rotating when
the engine is running and the clutch is engaged. Three direct and one reverse speeds are attained on
suitably moving the gear on the main shaft by means of selector mechanism.
Question:
1. The gearing of a machine tool is shown in Fig. The motor shaft is connected to gear A and rotates
at 975 r .p.m. The gear wheels B, C, D and E are fixed to parallel shafts rotating together. The
final gear F is fixed on the output shaft. What is the speed of gear F? The number of teeth on each
gear are as given below :
Gear A B C D E F
No. of theet 20 50 25 75 26 65
2. Two parallel shafts, about 600 mm apart are to be connected by spur gears. One shaft is to run at
360 r.p.m. and the other at120 r.p.m. Design the gears, if the circular pitch is to be 25 mm.
3. The speed ratio of the reverted gear train, as shown in Fig. 13.5, is to be 12. The module pitch of
gears A and B is 3.125 mm and of gears C and D is 2.5 mm. Calculate the suitable numbers of
teeth for the gears. No gear is to have less than 24 teeth.
Types of flat belt drive.
4. State the types of Gears. State and explain the types of gear trains.
Marks obtained: Signature of faculty: Date:
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
EXPERIMENT NO. 6
BALANCING
Masses m1, m2, m3, m4 are attached to the shaft in the same plane and rotating about the axis of the
shaft passing through the point `O’. The masses are rotating at the angular speeds of ω rad /sec and have
their C.G at a distance of r1, r2, r3 and r4 from the axis of the shaft respectively .The angular position of the
masses m1, m2, m3, m4 with respect to `OX’ is Θ1, Θ2, Θ3, Θ4 respectively .When the shaft rotates the
centrifugal force acts on it radially outwards through each mass center. Each of these forces will be
proportional to the corresponding products m.r.
There are two method of Balancing of several masses
Analytical Method.
Graphical Method.
Analytical method:-
The magnitude and direction of the balancing mass may be obtained, analytically, as discussed
below:
1. First of all, find out the centrifugal force (or the product of the mass and its radius rotation) of
exerted by each mass on the rotating shaft.
2. Resolve the centrifugal forces horizontally and vertically and find their sums, i.e.H And V .
We know that Sum of horizontal components of the centrifugal forces
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
∑ H = m1r1cos1 + m2r2cos2
and sum of vertical components of the centrifugal forces,
∑ V = m1r1sin1 + m2r2sin2
PREPARE SHEETS :-
1. Four masses m1, m2, m3 and m4 are 200 kg, 300 kg, 240 kg and 260 kg respectively. The corresponding
radii of rotation are 0.2 m, 0.15 m, 0.25 m and 0.3 m respectively and the angles between successive
masses are 45°, 75° and 135°. Find the position and magnitude of the balance mass required, if its radius
of rotation is 0.2 m.
2. Four masses A, B, Cand D are attached to a shaft and revolve in the same plane. The masses are 12 kg,
10 kg, 18 kg and 15 kg respectively and their radii of rotations are 40 mm, 50 mm, 60 mm and 30 mm.
The angular position of the masses B, C and D are 60°, 135° and 270° from the mass A. Find the
magnitude and position of the balancing mass at a radius of 100 mm.
3. A single cylinder reciprocating engine has speed 240 r.p.m., stroke 300 mm, mass of reciprocating parts
50 kg, mass of revolving parts at 150 mm radius 37 kg. If two-third of the reciprocating parts and all the
revolving parts are to be balanced, find : 1). The balance mass required at a radius of 400 mm, and
2).The residual unbalanced force when the crank has rotated 60° from top dead center.
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
Marks obtained: Signature of faculty: Date:
EXPERIMENT NO. 7
FLYWHEEL
AIM: To study about fly wheel and its function
THEORY:
Fly wheel:-
A flywheel used in machines serves a purpose of reservoir, which stores energy during the period
when the supply of energy is more than the requirement and release it during the period when the
requirement of energy is more than the supply thus flywheel control fluctuation.
Function of the flywheel:-
1. To control the fluctuation in input and output in machines because of speed variation during
the cycle.
2. To control the speed during working cycle. Mathematically flywheel controls Dn /DT.
3. During the period of working cycle when the speed increases, fly-wheel stores the energy and
when it is required.
4. Flywheel cannot control the quality of working media
5. Fly wheel are required only where the undesired fluctuation in speed or energy take place
during working cycle.
Turning moment diagram for four stroke cycle internal combustion engine:-
In this type of engine when crank turns for two revolutions the working cycle gets completed &one
working stroke is available during each cycle. During suction stroke the pressure in the cylinder is below
atmospheric pressure & hence negative loop of turning moment diagram is available for the portion of the
stroke. During compression work is done on the gas and hence negative loop of greater value is available
during this stroke. During working or expansion or expansion stroke the combustion of the fuel takes
place & power is produced to a large extent during this stroke & the gases expand giving large positive
loop of turning moment diagram. In the end during exhaust stroke the gases are paused out from the
cylinder through exhaust system & work is done on the gas as a result majority of negative loop of
turning moment is available during this stroke.
Uses of turning moment diagram:-
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
In the case of machines like steam engine I.C. engine power press, fly-press, crushes, it becomes
necessary to plot the turning moment diagram in order to carry out the force analysis.
The value of the maximum torque during the working cycle can be found out which is useful for the
design of crank shaft, flywheel & other element of the machines.
Question:
1. The mass of flywheel of an engine is 6.5 tones and the radius of gyration is 1.8 meters. It is found
from the turning moment diagram that the fluctuation of energy is 56 kN-m. If the mean speed of
the engine is 120 r.p.m., find the maximum and minimum speeds.
2. The turning moment diagram for a petrol engine is drawn to the following scales: Turning moment,
1 mm= 5 N-m; crank angle, 1 mm= 1°. The turning moment diagram repeats itself at every half
revolution of the engine and the areas above and below the mean turning moment line taken in
order are 295, 685, 40, 340, 960, 270 mm2. The rotating parts are equivalent to a mass of 36 kg at a
radius of gyration of 150 mm. Determine the coefficient of fluctuation of speed when the engine
runs at 1800 r.p.m.
3. The turning moment diagram for a multi cylinder engine has been drawn to a scale 1 mm= 600 N-m
vertically and 1 mm= 3° horizontally. The intercepted areas between the output torque curve and
the mean resistance line, taken in order from one end, are as follows:
+ 52, – 124, + 92, – 140, + 85, – 72 and + 107 mm2, when the engine is running at a speed of 600
r.p.m. If the total fluctuation of speed is not to exceed ± 1.5% of the mean, find the necessary mass
of the flywheel of radius 0.5 m.
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SHRI K J POLYTECHNIC, BHARUCH
MECHANICAL ENGINEERING DEPARTMENT
Marks obtained: Signature of faculty: Date:
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