Theory of machines & Machine Design

Tutorial 7.

Question 1.

A revolving shaft with machined surface carries a bending moment of 3000 Nm and a
torque of 9000 Nm with +/- 20% fluctuations. The stress concentration factors for
bending and torsion are equal to 1.35. The material has a yield strength of 620 Mpa
and endurance limit of 300 Mpa. Design a shaft of minimum diameter that will safely
handle these loads if the factor of safety is 2.0

Question 2.

C
A B

Design a shaft to support the attachment shown in the above figure with a minimum
design safety factor of 2.5. It must transmit 2 KW at 1725 rpm. The torque and the
force on the gear are both constant with time. Assume the v-belt tight and slack side
have tensions in the ratio of 5:1. Assume the spur gear is having pressure angle of 200
Sut = 450 Mpa Syt = 262 Mpa. Se = 200 Mpa
For diameter d1 portion Kb= 2.5 ; Kfs = 2.7
For diameter d2 portion Kb= 2.25 ; Kfs = 1.57
For diameter d3 portion Kb =2.25 ; Kfs = 1.57
Kb, Kfs – stress concentration factors due to keyways, fillet radius etc

Question 3.

Given d= 8 mm, y working = 19 mm, 15 % clash allowance, unpeened chrome

vanadium wire, square ends, F max = 100 kg, Fmin = 20 kg. Assume spring index of
8 and find number of active coils, Diameter of the spring, Shut height of the spring,
 free length of the spring, spring rate (spring constant) and the initial deflection. G =
200 Gpa. Also find the maximum shear stress in the material due to this loading.

Question 4.

A steel alloy spring with G = 77000 N/mm2 must be capable of exerting a force of P1
of 250 N in its most extended condition. After being compressed an additional
amount of ( δ 2 − δ1 ) of 20 mm. The torsional shearing stress τ 2 must not exceed 350
Mpa. Space limitations indicate that the mean helix radius should be about 15 mm.
Find the wire diameter, number of active coils, and the volume of material for
optimum spring

Question 5.

A static helical spring has to carry a static load of 600 N at a deflection of 30 mm.
Shearing stress is limited to 300 Mpa. End turns Q equals to 2. Find a suitable wire
diameter d for the most efficient spring. Choose the nearest available standard wire
size for the actual spring and find the corresponding values of R and Nc. Find the
volume of material in the spring. G = 79300 Mpa.

Question 6.

A helical compression spring made of No 4 music wire carries a fluctuating load. The
spring index is 8 and factor of safety is 1.2. If the average load on the spring is 600 N,
find the permissible values for the maximum and minimum
loads. τ yp = 648Mpa;τ e = 450Mpa

Please see the data given below

Design considerations for most efficient helical compression

spring with static load

c B c B c B c B c B
3.0 94 4.0 257 5.0 563 6.0 1006 7.0 1830
3.1 105 4.1 280 5.1 603 6.1 1130 7.1 1924
3.2 118 4.2 305 5.2 646 6.2 1196 7.2 2020
3.3 131 4.3 331 5.3 690 6.3 1346 7.3 2121
3.4 145 4.4 359 5.4 737 6.4 1337 7.4 2224
3.5 161 4.5 387 5.5 783 6.5 1412 7.5 2331
3.6 178 4.6 420 5.6 837 6.6 1489 7.6 2443
3.7 196 4.7 453 5.7 891 6.7 1570 7.7 2557
3.8 215 4.8 487 5.8 947 6.8 1654 7.8 2675
3.9 235 4.9 524 5.9 1005 6.9 1741 7.9 2798
4.0 257 5.0 563 6.0 1066 7.0 1830 8.0 2924
Stardard wire diameters

Steel spring wire

Wire gage Diameter d
no In
25 0.0204
24 0.023
23 0.0258
22 0.0286
21 0.0317
20 0.0348
19 0.041
18 0.0475
17 0.054
16 0.0625
15 0.072
14 0.08
13 0.0915
12 0.1055
11 0.1205
10 0.135
9 0.1483
8 0.162
7 0.177
6 0.192
5 0.207
4 0.2253
1/4" 0.25
5/16" 0.3125
3/8" 0.375