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List of Experiments
Sl. No. List of design of machine element Page No.

1. Design of shaft 8 – 11

2. Design of rigid coupling 12 – 14

3. Design of flexible coupling 15 – 17

4. Design of helical spring 18 – 22

5. Design of leaf spring 23 – 27

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 Experiment 1: Design of Shaft

1. AIM OF THE EXPERIMENT: Calculate the value of diameters of shaft for given loads and
layout.
2. OVERVIEW OF SHAFTS

• A shaft is a rotating member usually of circular cross-section (solid or hollow), which

transmits power and rotational motion.

• Machine elements such as gears, pulleys (sheaves), flywheels, clutches, and sprockets
are mounted on the shaft and are used to transmit power from the driving device (motor
or engine) through a machine.

• Press fit, keys, dowel, pins and splines are used to attach these machine elements on the
shaft.

• The shaft rotates on rolling contact bearings or bush bearings.

• Various types of retaining rings, thrust bearings, grooves and steps in the shaft are used
to take up axial loads and locate the rotating elements.

• Couplings are used to transmit power from drive shaft (e.g., motor) to the driven shaft
(e.g., gearbox, wheels).

3. DESIGNING OF SHAFT

Designing shaft is to calculated value its diameters at critical section. The critical section is a
section on the shaft which is highly stressed. The value stresses are calculated with the help of
layout and free body diagram.

➢ The shafts may be designed on the basis of:

➢ 1. Strength, and 2. Rigidity and stiffness.
➢ In designing shafts on the basis of strength, the following cases may be considered :
➢ Shafts subjected to twisting moment or torque only,
➢ Shafts subjected to bending moment only,
➢ Shafts subjected to combined twisting and bending moments, and
➢ Shafts subjected to axial loads in addition to combined torsional and bending loads.

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3.1. Considerations in shaft design:

o Size and spacing of components

o Material selection, material treatments
o Deflection and rigidity
o Stress and strength
o Frequency response
o Assembly, manufacturing & servicing constraints

4. LOADS ON SHAFT:

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5. FLOW CHART FOR SHAFT DESIGN:

6. COMMON FORMULA TO DESIGN SHAFT IN COMBINED LOADING:

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 L/k > 115

L/k < 115

Where alpha is column factor

di
k=
do
Km = Combined shock and fatigue factor for bending, and
Kt = Combined shock and fatigue factor for torsion.

Value of Km and Kt by using following table:

7. VALUE BENDING STRESS AND SHEAR STRESS IS OBTAINED FROM DESIGN

DATA BOOK FOR THE SELECTED MATERIAL:

Prob.
A hollow shaft of 0.5 m outside diameter and 0.3 m inside diameter is used to drive a propeller
of a marine vessel. The shaft is mounted on bearings 6 metre apart and it transmits 5600 kW
at 150 r.p.m. The maximum axial propeller thrust is 500 kN and the shaft weighs 70 kN.
Determine :
1. The maximum shear stress developed in the shaft, and
2. The angular twist between the bearings.

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 Experiment 2: Design of a rigid coupling

1. AIM OF THE EXPERIMENT: Find the value of dimensions of rigid coupling.

2. THEORY: Shafts are usually available up to 7 metres length due to inconvenience in

transport. In order to have a greater length, it becomes necessary to join two or more pieces of
the shaft by means of a coupling.
Purposes of couplings:
I. To provide for the connection of shafts of units that are manufactured separately such
as a motor and generator and to provide for disconnection for repairs or alternations.
II. To provide for misalignment of the shafts or to introduce mechanical flexibility.
III. To reduce the transmission of shock loads from one shaft to another.
IV. To introduce protection against overloads.
V. It should have no projecting parts.

The usual proportions for an unprotected type cast iron flange coupling, as shown in figure
above, are as follows :
If d is the diameter of the shaft or inner diameter of the hub, then

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Outside diameter of hub,
D = 2 (d)
Length of hub, L = 1.5 (d)
Pitch circle diameter of bolts,
D1 = 3(d)
Outside diameter of flange,
D2 = D1 + (D1 – D) = 2 D1 – D = 4 d
Thickness of flange, tf = 0.5 d
Number of bolts = 3, for d up to 40 mm
= 4, for d up to 100 mm
= 6, for d up to 180 mm

3. DESIGN FOR HUB

The hub is designed by considering it as a hollow shaft, transmitting the same torque (T) as that
of a solid shaft.

The outer diameter of hub is usually taken as twice the diameter of shaft. Therefore, from the
above relation, the induced shearing stress in the hub may be checked.
The length of hub (L) is taken as 1.5 d.
The material of key is usually the same as that of shaft. The length of key is taken equal to the
length of hub.

4. DESIGN FOR FLANGE

The flange at the junction of the hub is under shear while transmitting the torque. Therefore,
the torque transmitted,
T = Circumference of hub × Thickness of flange × Shear stress of flange × Radius of hub

5. DESIGN FOR BOLTS

The bolts are subjected to shear stress due to the torque transmitted. The number of bolts (n)

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depends upon the diameter of shaft and the pitch circle diameter of bolts (D1) is taken as 3 d.
We know that

Prob:

Design a cast iron protective type flange coupling to transmit 15 kW at 900 r.p.m. from an
electric motor to a compressor. The service factor may be assumed as 1.35. The following
permissible stresses may be used:

Shear stress for shaft, bolt and key material = 40 MPa

Crushing stress for bolt and key = 80 MPa

Shear stress for cast iron = 8 MPa

Draw a neat sketch of the coupling.

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 Experiment 3: Design of Flexible coupling

1. AIM OF THE EXPERIMENT: Find the value of dimensions of rigid coupling.

2. THEORY: Flexible coupling is used to join the abutting ends of shafts when they are not
in exact alignment. In a direct electric drive from an electric motor to a machine tool, a
flexiblecoupling is used so as to permit an axial misalignemnt of the shaft without undue
absorption of the power which the shaft are transmitting. Following are the different types of
flexible couplings :

1. Bushed pin flexible coupling, 2. Oldham's coupling, and 3. Universal coupling.

Bushed pin flexible coupling

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Since the pin is subjected to bending and shear stresses, therefore the design must be checked
either for the maximum principal stress or maximum shear stress by the following relations,

Prob.
Design a bushed-pin type of flexible coupling to connect a pump shaft to a
motor shaft transmitting 32 kW at 960 r.p.m. The overall torque is 20 percent more than
mean torque. The material properties are as follows :
(a) The allowable shear and crushing stress for shaft and key material is 40 MPa and 80
MPa respectively.
(b) The allowable shear stress for cast iron is 15 MPa.
(c) The allowable bearing pressure for rubber bush is 0.8 N/mm2.
(d) The material of the pin is same as that of shaft and key.
Draw neat sketch of the coupling.

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 Experiment 4: Design of Helical Spring

1. AIM OF THE EXPERIMENT: Design a helical spring based on given maximum force
and deflection to consider. Analyze the steps involved in designing the helical spring.

2. OBJECTIVE FOR THE DESIGN:

• The spring should possess sufficient strength to withstand the external load.
• It should have different load-deflection characteristic.
• It should not buckle under the external load.

3. TYPES OF SPRINGS:

Helical Torsional
spring Conical or volute spring

Disc spring Laminated or leaf spring

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3.1. Two basic types of helical spring:

(i) Compression spring: shorten under the action of external load

(ii) Extension spring: elongate under the action of external load

Compression helical Extension helical

4. HELICAL COMPRESSION SPRING DESIGN:

The main dimensions of a helical spring subjected to
compressive force are shown in the figure. They are:

• d = wire diameter of the spring (mm)

• Di = inner diameter of the spring (mm)
• Do = inner diameter of the spring (mm)

• D = mean diameter of the spring (mm)

D = (Di + Do) / 2
• p = pitch of the spring (mm)
• C = Spring index = D / d
➢ For lower C values (C < 3): The actual stresses in the wire
are excessive due to curvature effect.
➢ For higher C values (C > 15): Spring is prone to buckling and tangle easily during
handling.
➢ A spring index from 4 to 12 is considered best from manufacturing conditions.

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5. TERMINOLOGIES USED IN HELICAL SPRINGS:

➢ Solid Length: It is defined as the axial length of the spring, which when compressed, the
adjacent coils touch each other. No compression is possible beyond this point.
Solid length = Ntd, Nt = Total no. of coils.
➢ Compressed Length: It is defined as the axial length of the spring, which is subjected to
maximum compressive force. In this case, the spring is subjected to a maximum deflection of
δ. Some gap is provided between the adjacent coils to prevent their clashing.

Clashing allowance = 15% of maximum deflection. Also, 1 - 2 mm gap between the adjacent coils
is provided as a thumb rule.

Total gap = (Nt - 1)xGap between adjacent coils.

➢ Free Length: It is defined as the axial length of the unloaded spring. In this case, no external
force acts on the spring.
Free length = compressed length + δ
= solid length + total axial gap + δ

➢ Pitch: It is defined as the axial distance between the adjacent coils in the uncompressed state.
p = free length/(Nt - 1)
➢ Stiffness: k = P/ δ
P = Axial Spring Force
δ = Axial deflection of spring corresponding to force P.

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6. PROCEDURES FOR DESIGNING A HELICAL SPRING:
The basic procedure for the design of helical spring consists of following steps :
(i) For the given application, maximum spring force (P) and corresponding deflection (δ) are to be estimated.
In some cases, maximum spring force (P) and the stiffness (k) of the spring is specified.

(ii) A suitable spring material is to be selected and its ultimate tensile strength has to be ascertained. The
permissible shear stress for the spring wire is estimated by :
τP = (0.3 - 0.5)σ UT

(iii) Depending on the application, appropriate spring index (C) has to be choosen. In general, a 'C' value of
8 is considered as a good value. However, 'C' value should not be less than 3.

(iv) The Wahl's factor is to be calculated using the following relationship :

4C - 1 0.615
KW = +
4C - 4 C

(v) The wire diameter (d) is evaluated using the following eqn,
8PD 8PC
τ = KW =K
3 W 2
πd πd

(vi) The mean diameter (D) of the coil is obatined using,

D = Cd

(vii) The number of active coils is determined using the following eqn,
3
8PD N
δ= 4
Gd

(viii) Depending upon the type of the ends for a spring, the no. of inactive coils are determined. Total no. of
coils (Nt ) can be found out by adding no. of active and inactive coils.

(ix) The solid length of the spring = N t d

3
8PD N
(x) Actual deflection δ =
4
Gd

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(xi) Total axial gap between the coils = ( N t - 1) x gap between adjacent coils. In some cases, total gap is
taken as 15% of the maximum displacement.

(xii) Free length of the spring is to be determined using,

Free length = Solid length + total gap + δ

(xiii) Pitch (p) of the spring is found out as,

Free length
p =
( N t - 1)

(xiv) The stiffness (k) is calculated using,

4
Gd
k =
3
8D N

Experiment 5: Design of Leaf Spring

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1. AIM OF THE EXPERIMENT: Find dimension of leave spring and assure that the value
of stresses are within the limit.
2. THEORY:

Leaf springs (also known as flat springs) are made out of flat plates. The advantage of leaf
spring over helical spring is that the ends of the spring may be guided along a definite path as
it deflects to act as a structural member in addition to energy absorbing device. Thus the leaf
springs may carry lateral loads, brake torque, driving torque etc., in addition to shocks.

L = length of the cantilever or half the length of semi-elliptic spring (mm)

P = force applied at the end of the spring (N)

Pf = portion of P taken by the extra full-length leaves (N)

Pg = portion of P taken by the graduated-length leaves (N)

The group of graduated-length leaves along with the master leaf can be treated as a triangular
plate, as shown in Fig. give in next slide. In this case, it is assumed

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 • The deflection at the load point is given by,

Since the deflection of full-length leaves is equal to the deflection of graduated-length leaves,

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Bending stresses in full-length leaves are 50% more than those in graduated-length leaves.

3. NIPPING OF LEAF SPRINGS

One of the methods of equalising the stresses in different leaves is to pre-stress the spring. The
pre-stressing is achieved by bending the leaves to different radii of curvature, before they are
assembled with the centre clip. The initial gap C between the extra full-length leaf and the
graduated-length leaf before the assembly, is called a ‘nip’.

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The deflection at the end of the spring is determined as given below:

The deflection of the multi-leaf spring due to the external force P is the same

Prob:
A semi-elliptic leaf spring used for automobile suspension consists of three extra full-length leaves
and 15 graduated-length leaves,
including the master leaf. The centre-to-centre distance between two eyes of the spring is 1 m. The
maximum force that can act on the spring is 75 kN. For each leaf, the ratio of width to thickness is 9:1.
The modulus of elasticity of the leaf material is 207 000 N/mm2. The leaves are pre-stressed in such a
way that when the force is maximum, the stresses induced in all leaves are same and equal to 450
N/mm2. Determine
(i) the width and thickness of the leaves;
(ii) the initial nip; and
(iii) the initial pre-load required to close the gap C between extra full-length leaves and graduated-
length leaves.

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