Enroll.

No:

MACHINE DESIGN-II

LABORATORY MANUAL

B.E.-IV SEM.-VIII

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 MECHANICAL ENGINEERING DEPARTMENT

CERTIFICATE

This is to certify that Mr./Ms./Mrs._______________________

Enroll. No ._________________of __________________________

Class has satisfactory completed the course in

____________________________________________________

Date of Submission: ____________________________

Concern Faculty: ______________________________

Head of Department: __________________________

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 INDEX
Sr. Title Page Date Completion Initial Gr
No From To of date of
Start faculty
1. Design Considerations ,

2. Study and Design of Gears

3. Design of Gearbox

4. Design of Hoisting elements

5. Design of I.C. Engine

Components(1)
6. Design of I.C. Engine
Components(2)

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 * INSTRUCTIONS *

LABORATORY WORK:
 A total hour of engagement for laboratory work of the subject is twenty four.
 During the laboratory sessions students are required to make Electronic models of the
component designed by them using Pro/Engineer wildfire 2.0 software.
 After completion of all the models assembly of the components is to be prepared.
 Before coming to the laboratory student should solve the problems given to them and
prepare a sketch of the same in the sketchbook which can be referred for preparing
the model.
 Students should prepare their sheets as per following sequence.

IMPORTANT GUIDELINES

 Before starting each sheet in the college, signature of concerned batch teacher should
be taken on the sheet without fail, else no credit would be given to that practical sheet.

 Before starting each sheet in the college, each student will have to ensure that the
work in the sketch book pertaining to that sheet is completed in all respect, else the
student will not be permitted to start his/her work in the sheet.

 All the Problems have to be solved by the students in their sketchbook, irrespective of
the batches, prior to the scheduled date of respective practical.

 In the sketch book all the Problems of one sheet should be drawn in continuation to
avoid Problems during evaluation.

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 Teaching and Examination Scheme
‘2013-2014
* Syllabus *
(As per GTU)
B.E.-IV SEM VIII (Mechanical ENGG)
181902 Machine Design-II
Subject Code Teaching Scheme Examination Scheme
Theory Tutorial Exam Theory Theory Marks TW Total
Paper
MACHINE DESIGN-II 181902 03 01 Internal 1.30 Hrs 30 50 150
+ External 3 hrs 70

1. SPUR GEARS AND PARALLEL AXIS HELICAL GEARS (07 hrs )

Gear Terminology, Speed ratios and number of teeth, Force analysis, Tooth stresses, Dynamic effects, Fatigue
strength, Factor of safety, Gear materials, Module and Face width-power rating calculations based on strength
and wear considerations

Parallel axis Helical Gears:

Pressure angle in the normal and transverse plane, Equivalent number of teeth-forces and stresses. Estimating
the size of the helical gears.

2. BEVEL AND WORM GEARS: (07 hrs)

Straight and spiral bevel gear: Tooth terminology, tooth forces and stresses, equivalent number of teeth.
Estimating the dimensions of pair of straight and spiral bevel gears. Worm Gear: Merits and demerit, -
terminology, Thermal capacity, materials, forces and stresses, efficiency, estimating the size of the worm gear
pair.

3. DESIGN OF GEAR BOXES (05 Hrs)

Geometric progression - Standard step ratio - Ray diagram, kinematics layout – Design of sliding mesh gear box
-Constant mesh gear box, Design of multi speed gear box.

4. DESIGN OF I .C. ENGINE COMPONENTS: (14 hrs)

Selection of type, general design consideration, design of cylinder, cylinder liner, cylinder head, pistons,
connecting rod, crank shaft, valves gears mechanism, flywheel.

5. DESIGN OF MATERIAL HANDLING EQUIPMENTS: (12 hrs)

Introduction: material handling equipments, classification and their selection. Concept of material handling
system design.

Lifting Equipments: classification and selection and design of hooks, sheaves, drums and grab buckets.
Classification of cranes, construction working of different types of conveyors, feeders and elevators.\

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Conveying equipments: classification construction and working of different types of conveyors, feeders and
elevators. Design of belt conveyors, screw conveyors and vibratory conveyors.

Term Work: The term work shall be based on the topics mentioned above.
Practical / Oral: The candidate shall be examined on the basis of term-work.
Books:
1. Joseph E. Shigley & Larry D. Mitchell, “Mechanical Engineering Design”, Fourth
Edition, McGraw-Hill International Book Company.
2. Design of machine Elements by Bhandari , Tata McGraw-Hill Publishing Company Ltd
3. Machine Design by Sharma-Agarwal, S.K.Kataria & Sons
4. Machine Design by Sadhusingh, Khanna Publishers,
5. Machine Design by R.S.Khurmi & J.K.Gupta, S.Chand & Co.
6. Transmission System Design by R.B.Patil, TechMax Pub., Pune.
7. Machine Design Vol-II & III by F.Haideri, Nirali Prakashan, Pune.
8. Bearing Manufacturers Catalogues
9. PSG Design Data Book.

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 * Units *
SI base units
Expression in terms of Expression in terms of SI
Name Symbol Quantity
other units base units
Newton N Force, Weight m∙kg/s2 m∙kg∙s−2
Energy, Work,
joule J N∙m m2∙kg∙s−2
Heat
watt W Power J/s m2∙kg∙s−3
Pascal Pa Pressure, Stress N/m2 m−1∙kg∙s−2

Some Important Derived Units

Expression in terms
Name Symbol Quantity
of SI base units
square metre m2 area m2
cubic metre m3 volume m3
metre per second m·s−1 speed, velocity m·s−1
metre per second
m·s−2 acceleration m·s−2
squared
radian per second rad·s−1 angular velocity s−1
momentum,
Newton second N·s kg·m·s−1
impulse
Newton metre second N·m·s angular momentum kg·m2·s−1
torque, moment of
Newton metre N·m kg·m2·s−2
force
density, mass
kilogram per cubic metre kg·m−3 kg·m−3
density
cubic metre per kilogram kg−1·m3 specific volume kg−1·m3
Mass Moment of
Mass Moment of Inertia kg·m2 kg·m2
Inertia

PRACTICAL: 1
DESIGN CONSIDERATION IN MACHINE DESIGN

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AIM: Design Consideration in machine design

INSTRUCTIONAL OBJECTIVES
At the end of this lesson, the students should have the knowledge of

• Basic concept of design in general.

• Concept of machine design and their types.
• Factors to be considered in machine design.

INTRODUCTION

Design is essentially a decision-making process. If we have a problem, we need to design a

solution. In other words, to design is to formulate a plan to satisfy a particular need and to
create something with a physical reality.

EXERCISE

1) Explain the general consideration in machine design.

2) Explain the general procedure in machine design.
3) Explain the casting, welding, process for design component.
4) Explain the forging, hot and cold working, machining, welding process
5) Discuss the Design for creep – thermal considerations – wear considerations in design
– Human considerations in design.

Date:- Sign:- Grade:-

PRACTICAL: 2
DESIGN OF GEARS

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AIM: DESIGN OF GEARS.

INTRODUCTION
1. Introduction gears
2. Classification of gear and their applications
3. Spur Gear
4. Helical Gear
5. Double helical or Herringbone Gear
6. Bevel Gear
(a)Straight (b) Spiral (c) hypoidal
7. Crossed helical gear
8. Law of gearing
9. Gear profiles
10. Meshing of gears

DESIGN OF GEAR

CONTENTS
1. Surface durability –basic concepts
2. Surface failures
3. Buckingham contact stress equation
4. Contact stress –AGMA procedure
5. Surface fatigue strength – AGMA procedure
6. Permissible contact stress

EXERCISE OF GEARS

1) Write down the complete design procedure for spur gear.

2) The following particulars of a single reduction spur gear are given:
Gear ratio = 10:1, Distance between centres= 660mm approximately, pinion transmit 500kw
at 1800 r.p.m Involute teeth of standard proportion with angle of 22.5°; Permissible normal
pressure between teeth = 175N per mm of width. Find
1) The nearest standard module
2) The number of teeth on each wheel.
3) The necessary width of pinion.
4) The load on bearing of the wheels due to power transmitted.

3) In a conveyor system a step-down gear drive is used. The input pinion is made of 18 teeth,
2.5 mm module, 200 full depth teeth of hardness 330 Bhn and runs at 1720 rpm. The driven
gear is of hardness 280 Bhn and runs with moderate shock at 860 rpm. Face width of wheels

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is 35 mm. The gears are supported on less rigid mountings, less accurate gears and contact
across full face may be assumed. The ultimate tensile strength of pinion and gear materials
are 420 and 385 MPa respectively. The gears are made by hobbing process. Find the tooth
bending strength of both Wheels and the maximum power that can be transmitted by the
drive with a factor of safety 1.5.
The layout diagram is shown in the figure.
Conveyor drive Layout diagram.

4) Explain complete design procedure for helical gear, and its application.

5) Design of pair of helical gears for transmitting 22kw. The speed of the driver gear is 1800
r.p.m. and that of driven gear is 600 r.p.m. the helix angle is 30 0 and profile is
corresponding to 20 full depth system. The driver gear has 24teeth. Both the gears are
0

made of cast steel with allowable static stress as 50MPa. Assume the face width parallel to
axis as 4 times the circular pitch and the over hang for each gear as 150mm. the allowable
shear stress for the shaft material may be taken as 50MPa. The form factor may be taken
as 0.154-0,912/TE , where TE is the equivalent number of teeth. The velocity factor may be
taken as 350/ (350 + v), where v is the pitch velocity in m/min. The Gears are required be
designed only against bending failure of the teeth under dynamic condition.

6) A 75 kW induction motor runs at 740 rpm cw direction. The motor is keyed to a 19 tooth
helical pinion having 200 normal pressure angle, 230 helix angle and 10 mm normal module.

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Draw a 3- dimensional sketch of the motor shaft and pinion and show the forces acting on the
pinion and the bearing reaction at A and B. The thrust should be taken out at A.

Data: P=75kW, n1=740rpm

Z1 = 19, Z2 = 38, Øn=200,
ψ = 230, mn = 10 mm

7) Explain the number of terms used for the bevel gear.

8) Explain complete Design procedure for bevel gear.
9) A pair of full depth involute teeth bevel gears of two shaft at right angle having velocity
3:1. The gear is made of cast steel having allowable static stress as 70Mpa and the pinion is
of steel with allowable static stress as 100Mpa. The pinion transmits 37.5kw at 750r.p.m
Determine 1) module and face width, 2) Pitch diameter and,3) pinion shaft diameter.
Assume tooth form factor, y = 0.154 – 0.912/T E, where TE formative number of teeth, width
= 1/3rd the length of pitch cone, and pinion shaft overhang by 150mm.

10) A pair of cast iron bevel gears connect two shafts at right angles. The pitch diameters of
the pinion and gear are 80mm and 100mm respectively. The tooth profiles of the gears are of

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14 ½ 0 composite form. The allowable static stress for both the gears is 55MPa. If the pinion
transmits 2.75KW at 1100 r.p.m find the module and number of teeth on each gear from the
stand point of strength and check the design from the stand point of wear. Take surface of
endurance limit as 630MPa and modulus of elasticity for cast iron as 84kn/mm 2 .

11) Explain the types of worm gear and terms used for worm gearing.
12) Discuss about strength and wear tooth load on worm gear.
13) Give thermal rating of worm gearing.
14 Different force acting on worm gears.
15) Design of worm gearing.

16) Design 22° involute worm and gear to transmit 10kw with worm rotating at 1400r.p.m. and
to obtain a speed reduction of 12:1. The distance between the shaft is 225mm.

17) Design worm and gear speed reducer to transmit 22kw at a speed of 1440r.p.m. the
desired velocity ratio is 24:1. An efficiency at least 85% is desired. Assume that the worm is
made of Hardened steel and the gear of phosphor bronze.

Date:- Sign:- Grade:-

PRACTICAL: 3
DESIGN OF GEAR BOX

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AIM: Design of Gear Box

INTRODUCTION:

EXERCISE FOR GEAR BOX

1) Design procedure for gear box.

2) Selection of gear box.
3) In a turbine drive 300 kW power is transmitted using a pair of double helical gear. The
pinion speed is 2950 rpm and that of the gear is about 816.5 rpm. There are no space
constraints on the gear drive. Selecting suitable materials, design the pinion and the
gear to last for 108 cycles. Design the gearbox completely.
Data: W = 300kW; n1 = 2950rpm; n2 ≈ 816.5 rpm;
Life 108 cycles.

COMMERCIAL DOUBLE HELICAL GEAR BOX

4) In a turbine drive 250 kW power is transmitted using a pair of double helical gear. The
pinion speed is 2800 rpm and that of the gear is about 615 rpm. There are no space
constraints on the gear drive. Selecting suitable materials, design the pinion and the
gear to last for 108 cycles. Design the gearbox completely.
Data: W = 250kW; n1 = 2800rpm; n2 ≈ 615 rpm;

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 Life 108 cycles.

5) Design a worm gear set to deliver 12 kW from a shaft rotating at 1500 rpm to another
rotating at 75 rpm. Design a complete gearbox.

Date:- Sign:- Grade:-

PRACTICAL: 4
DESIGN OF HOISTING ELEMENTS

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AIM: DESIGN OF HOISTING ELEMENTS

INTRODUCTION
 Design of wire rope
 Design of hoisting Chains
 Design of Sheaves,
 Design of hooks and related component.

EXERCISE

1) Explain the function and construction of wire rope.

2) Discuss the number of stresses on the wire rope.
3) Explain Idlers and guide sheaves.
4) Explain the sheave and drum diameter.

5) Select the wire rope for a vertical mine hoist to lift 1250 tonnes of coal from a depth of
720meters in 8hours shift. Assume a two compartment shaft with the hoisting skip in
balance. Assume rope velocity = 720m.p.m and allow acceleration and deceleration
periods of 10second. Each and rest period of 10sec. for the discharging and loading.
Safety factor should be at least 5 for this application. Assume average tensile strength
of rope = 5900d2 kg (where d= dia of rope in cm for 6 X 19 wire rope.)
6) Design a chain drive to actuate a compressor from a 20H.P electric motor at 970 rpm,
the compressor rpm being 330. Minimum centre distance should be 550mm. the chain
tension may be adjusted by shifting the motor on rails. The compressor is work
16hr/day.

Date:- Sign:- Grade:-

PRACTICAL: 5
DESIGN OF I.C. ENGINE COMPONENT(1)

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AIM: To Design of I.C.Engine component (1).

INTRODUCTION
 Design of Cylinder
 Design of Piston

EXERCISE (A) DESIGN OF CYLINDER

1) 4 stroke diesel engine has the following specifications.

B.P = 5kw
Speed= 1200 rpm
Indicated mean effective pressure = 0.35n/m2
Determine:-
(1) Bore and length of cylinder.
(2) Thickness the cylinder head.
(3) Size of studs for the cylinder head.

2) 4 – stroke internal combustion engine has the following specification.

B.P = 75kw
Speed = 1000rpm
Indicated mean effective pressure = 0.35N.mm2
Maximum Gas pressure = 3.5N/mm2
Mechanical Efficiency = 80%
(1) The dimensions of the cylinder if the length of stroke is 1.4 time of the bore of the cylinder.
(2) Wall thickness of the cylinder if hoop stress is 35Mpa
(3) Thickness of the cylinder head and the size of studs.

EXERCISE (B) DESIGN OF PISTON

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1) Design of cast iron piston on single acting four stroke engine for following data:

Cylinder Bore=100mm
Stroke =125mm
Maximum gas pressure = 5N/mm2
Indicated mean effective pressure = 0.75 N/mm2
Mechanical efficiency = 80%
Fuel consumption = 0.15kg/breake power/hour
Speed = 2000rpm
Any other data required may be assumed.

2) Design of cast iron trunk type piston for a single acting four stroke engine developing
75kw/cylinder when running at 600rpm. The outer available data is as follows.

Maximum gas pressure = 4.8 N/mm2

`
indicated mean effective pressure = 6.65 N/mm2
Mechanical efficiency = 95%
Radius of crank = 110mm
Fuel consumption = 0.3 kg/bp/hr
Calorific value of fuel = 44 x 103 kg
Available bearing pressure on piston barrel = 0. 4 N/mm2
Available bearing pressure on gudgeon pin = 17 N/mm2

Date:- Sign:- Grade:-

PRACTICAL: 6
DESIGN OF I.C. ENGINE COMPONENT(2)
AIM: To Design of I.C.Engine component (2).

INTRODUCTION

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EXERCISE (A) DESIGN OF CONNECTING ROD

Design of connecting rod for four stroke petrol engine with following data.
Diameter of piston: 8.8 cm
Stroke: 12.5 cm
Weight of reciprocating parts: 16 kg
Length of connecting rod center to center: 30 cm
R P M: 2200 with possible over speed of 3000.
Compressor ratio: 6.8:1
Probable maximum expansion pressure (assumed shortly after dead center, say Φ=3 0) =
35kg/cm2.

EXERCISE (B) DESIGN OF CRANK SHAFT

1) Design a plain carbon steel centre crankshaft for a single acting 4 stroke single cylinder
engine for the following data.:

Bore = 400mm
Stroke = 600mm
Engine speed = 200rpm
Mean effective pressure = 2.5 N/mm2
Weight of flywheel used as a pulley = 50 KN
Total bolt pull = 6.5 KN

2) Design a single throw double view crank shaft made of forged steel for a single cylinder,
horizontal I C engine having cylinder diameter of 120mm and 160mm stroke. The engine
redevelops 12.5 metric HP at 300 rpm. The explosion pressure is 25kg/cm 2(Gauge). The
maximum torque is developing when the crank shaft turns through 25 0 from inner dead center
position during the expansion stroke. The burnt (exploded) gas pressure at that moment is
21kg/cm2. The crank shaft main bearings are 32cm center to center. A third side bearing is

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placed 60cm center to center from one of the main bearings on its side. A flywheel which
weight 320kg and a belt driving pulley of 55cm diameter are placed between the main
bearing and outer bearing as shown in figure. The ratio of connecting rod length to radius is
4.5. Coefficient of friction μ between the leather belt and pulley rim may be assumed as
0.3(maximum). And the angle of lap of the belt may be assumed as 180 0. Maximum
permissible design stresses in forged steel are St=Sc=700kg/cm2 Ss= 420kg/cm2 allow
reasonable bearing pressure on crank shaft and crank pin bearing.

EXERCISE (C) DESIGN OF CAM SHAFT

1) Design a plain carbon steel centre camshaft for a single acting 4 stroke single cylinder
engine for the following data.:

Cylinder bore = 140mm

Stroke length = 270mm
Rpm (N) = 475
The valve opens 330 before outer dead centre its opens and closes with Constant
acceleration and deceleration for each half of the lift.

EXERCISE (D) DESIGN OF FLUCTUATING LOAD

1) A rectangular plate with the centre hole is subjected to a completely reversed axial load of
20KN as shown in fig. the determine plate thickness.

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2) Circular bar of 500mm length is supported freely at its two ends. It is acted upon by a
central concentration cyclic load having a minimum value of 20KN and maximum value of
50KN determine the diameter of bar by taking factor of safety of 1.5, size effect of 0.85
surface finish factor 0.9. The material properties of bar are given by ultimate strength of 650
Mpa, yield strength of 500 Mpa and endurance strength of 350Mpa.

3) Determine the thickness of 120mm wide uniform plate for safe continuous operation if the
plate is to be subjected to a tensile load that has a maximum value of 250KN and minimum
value of 100KN. The properties of the plate material are as follows
Endurance limits stress = 225Mpa
Yield point stress = 300Mpa
Factor of Safety = 1.5

Date:- Sign:- Grade:-

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