DEPARTMENT OF MECHANICAL ENGINEERING

S7 ME MACHINE DESIGN - I (Contact) Assignment No. 4 To be submitted on 28-08-2017

1. A shaft made of C-40 steel and 2.2m long, is supported by two bearings, one at the left end and another at 1.7m from
the left. The shaft carries two pulleys keyed to it, one at mid-span and another at the right end. The pulleys are of
diameter 0.6m and 0.5m respectively. Input power at the left pulley is 24 kW and the power output is from the right
pulley. The input to the left pulley is horizontal and the drive from the right pulley is to a machine vertically below.
Speed of the shaft is 600 r.p.m. and the coefficient of friction is 0.3. Combined shock and fatigue factors in bending
and torsion may be taken as 2.0 and 1.5 respectively. Design the shaft assuming suitable stresses. Also, design
suitable keys for connection between the shaft and the pulleys.
2. Determine the diameter for a hollow shaft having inside diameter 0.6 times the outside diameter. The maximum
allowable shear stress for the shaft is 80 MPa. The shaft is driven by a 750mm diameter overhung pulley placed
vertically below it. The weight of the pulley is 600 N. The tensions on tight and slack sides of the belt are 3.2 kN
and 1.2 kN respectively. The overhung is 250mm. Assume angle of lap of the belt on the pulley to be 180.
3. A horizontal solid shaft is supported on two bearings 1.5 m apart. A helical gear (45 helix angle) of 20 involute
teeth and 200 mm pitch diameter is located 400 mm to the right of the left bearing. The gear is driven by a mating
gear directly behind it. A 600 mm diameter pulley is keyed to the shaft 600 mm to the left of the right bearing. The
pulley drives another pulley with a horizontal belt directly behind it. The ratio of tensions of the belt is 2.8 with the
slack side on top. The drive transmits 30 kW at 300 rpm. Design the shaft if the allowable shear stress for the shaft
material is 40 N/mm2.
4. Determine the inside and outside diameters of a hollow shaft which will replace a solid shaft of the same material.
The hollow shaft should have the same strength as that of the solid shaft, but must weigh half the solid shaft per metre
length.
5. A 600mm pulley, P, driven by a horizontal belt transmits 20 kW of power
at 300 r.p.m. through a solid steel shaft to a 20 spur gear, G, of diameter
250 mm, which drives a mating gear directly behind it (figure-1). The
pulley weighs 1000 N and the ratio of tensions between the two sides of
the belt is 3.2. The shaft is supported between narrow bearings B 1 and B2
and both the pulley and the gear are keyed to the shaft. If commercial
steel shafting is used and the shock and fatigue factors are chosen to be
Kb = 2.0 and Kt = 1.5, determine the necessary diameter of the shaft.
Figure-1
6. A shaft and a key are made of the same material and the key width is of the shaft diameter. Considering shear
only, determine the minimum length of the key in terms of the shaft diameter. The shearing strength of the key
material is 60% of its crushing strength. Determine the thickness of the key to make the key equally strong in shear
and crushing.
7. A hollow shaft is to transmit 20 kW at 300 rpm. The loading is such that a maximum bending moment of 1000 Nm is
induced in the shaft, together with an additional axial thrust of 15 kN. The shaft is supported on bearings 1500 mm
apart. The values of shock and fatigue factors in torsion and bending (Kt and Kb) are 1.25 and 1.75 respectively. The
inside diameter is 0.8 times the outside diameter. Determine the outer diameter of the shaft if the allowable shear
stress is 60 MPa.
8. Determine the outer diameter of a hollow shaft having inside diameter 0.6 times the outside diameter. The maximum
allowable shear stress for the shaft is 85 MPa. The shaft is driven by a 900mm diameter overhung pulley placed
vertically below it. The weight of the pulley is 600 N. The tensions on tight and slack sides of the belt are 2.9 kN
and 1 kN respectively. The overhung length is 250mm. Assume angle of lap of the belt on the pulley to be 180.
9. Design and sketch a protected type of C.I. flange coupling for a
mild steel shaft transmitting 18 kW at 200 r.p.m. Shaft and key
are of the same material. Bolts are made of alloy steel for which
the maximum shear stress should not exceed 30 MPa. The
maximum torque may be taken as 25% greater than the full-load
torque.
10. A flexible coupling (shown in figure-2) is used to transmit 15 kW
of power at 100 r.p.m. There are six pins and their pitch circle
diameter is 200 mm. The length of the pin in contact with the
left hand flange, the gap between the two flanges and the length
of bush in contact with the right hand flange are 23, 5 and 35 mm
respectively. The permissible shear and bending stresses in the
pin are 35 and 152 N/mm2 respectively. The permissible
pressure for the rubber bush is 1 N/mm2. Calculate: (i) the pin
diameter by shear consideration, (ii) the pin diameter by bending
consideration and (iii) outer diameter of the rubber bush.
Figure-2