EXPERIMENT1

AIMDesignanddrawingofCotterJoint
FUNCTIONAcotterjointisusedtoconnectoneendofarodisprovidedwitha
sockettypeofendandtheotherendoftherodisinsertedtoasocket.Theendof
therodwhichgoesintoasocketisalsocalledSpigot.
APPLICATIONS
1. Jointsbetweenthepistonrodandthecrossneedofthesteamengine.
2. Jointsbetweenthesidespindleandtheforkofthevalvemechanism.
3. Jointbetweenthepistonrodandthetailorpumpfoundationbolts.
ASSUMPTIONS
1. Therodsaresubjectedtoaxialtensileforcetheeffectofsteels
concentrationduetoshaftisneglected.
NOTATION
F=Axialloadcarriedbytherod
d=Diameteroftherod
d1=diameterofspigot
d2=diameterofcollar
d3=outsidediameterofsleeve
d4=diameterofsleeveorsocket
a=widthatrodend
b=widthofcollar
c=widthofsocketend
e=Thicknessofcollar
t=thicknessofcotter

=allowableshearstress
c=allowablecrushingstress

PROCEDURE:
STEP1:Designofrods
Fortherodsunderaxialload,
Axialstressintherods,=4F

d2

STEP2:DesignofthespigotandtheCotter
a.) Crushingstrengthofthecotter,F=d1tc
b.) Axialstressacrosstheslotoftherod
=4F
(d1)24d1t
STEP3:Designofthecotter
StrengthofthecotterindoubleshearF=2bt
STEP4:Designofthecollar
a.) Bearingstressinthecollar,c=4F
{(d2)2(4d1)2}
b.) Shearstressinthecollar,=F

d1e

STEP5:Designofthesleeve
a.) Axialstressacrosstheslotofthesleeve
=4F
[(d3)2(d1)2]4t(d3d1)

b.) Crushingstrengthofthesocket
F=(d4d1)txc

STEP6:Designoftherodend
a.) Shearstressattherodendduetodoubleshear

=F

2ad1
STEP7:Designofthesocketend
Shearstressatthesocketend,=F
2c(d4d1)


EXPERIMENT2
AIMDesignofshaftssubjectedtoTorsion,BendingMomentandCombined
Bending&Torsion
INTRODUCTIONShaftusuallyaroundmember,solidorhollowcrosssectionthat
rotatesandtransmitspower.Itcarriesmachineelementslikegears,pulleys,
cams,sprockets,couplingsetc.Itsdesignprimarilyconsistsoffindingthesizein
ordertosatisfythestrengthandrigidity,whiletransmittingpower.Shaftsare
usuallysubjectedtotorsion,bendingetc.

NOTATIONS
P=PowerinkW
n=speedinrpm
Mb=Maximumbendingmomentonshaft
Mt=Maximumtorqueonshaft
D=Diameterofshaft

F=axialorthrustload
Kb=CombinedshockandEndurancefactorinBending
Kt=CombinedshockandEndurancefactorintorsion
Forrotatingshaftswithgraduallyappliedloads
Kb=1.5andKt=1.0
Suddenly,appliedloadswithminorshocks,Kb=1.5to2.0andKt=1to1.5
Suddenly,appliedloadswithheavyshocks,Kb=2.0to3.0andKt=1.5to3.0
=allowabletensilestressforshaftmaterial
=allowableshearstressforshaftmaterial
SHAFTSSUBJECTEDTOPURETORSION
SolidShaft:Diameterofshaft,D=16KtMt1/3

SHAFTSSUBJECTEDTOPUREBENDING
SolidShaft:Diameterofshaft,D=32KbMb1/3

SHAFTSSUBJECTEDTOCOMBINEDBENDINGANDTORSION
SolidShaft:
i.

ii.

Accordingtomaximumnormalstresstheory
DiameterofShaft,D=16KbMb+(KbMb)2+(KtMt)21/3

Accordingtomaximumshearstresstheory
DiameterofShaft,D=16(KbMb)2+(KtMt)21/3


EXPERIMENT3
AIMDesignofFlatandSquareKeys
INTRODUCTION
Keysareusedtopreventrelativemotionbetweenashaftandtheconnected
memberthroughwhichtorqueisbeingtransmitted.CommontypesofKeysare:
Squarekey,Rectangularkey,Featherkey,Roundkey,Gibkey,Headkey,Taper
key,Barthkey,Kennedykey,SaddlekeyandWoodruffkeyetc.
DESIGNOFSQUAREANDFLATKEY
Thekeysaresubjectedtoshearandcrushingorbearingstresswhiletransmitting
torque.


NOTATIONS
b=widthofkey
h=thickness
l=lengthofkey
Consideringtheshearingofkey
Shearstress,=F=F
Areaofshearbl
a.) WhereF=Force=Torque=Mt=Mt=2Mt
Radiusofshaftr(d/2)d
=2Mt=>widthofthekeyb=2Mt
dlb

dl

Consideringcrushingofkey
Crushingstress,c=F=F
Areaofcrushing(h/2)l
c=2Mt=4Mt=>thicknessofkeyh=4Mt
d(h/2)ldhldlc
ForSquarekeyb=h
b=2Mtandh=b=4Mt
dhdlc
Mt=bdlinshearandMt=bdlcincrushing
4


ProcedureType1:LengthofKey
STEP1:FindTorque,Mt=9.55x106xPP=PowerinkW,n=speed,rpm

STEP2:Diameterofshaft,d=316Mt
s
s=allowableshearstressforshaftmaterial
STEP3:Findlengthofkeyfrom
a.) Widthofkey,b=2Mt
dlk
k=allowableshearstressforkey
b.) Thicknessofkey,h=4Mt
dlb'
Recommendthebiggeroneaslength.
b'=allowablecrushingstressorbearingstressforkey.

ProcedureType2:Lengthofkey
STEP1:Torque,Mt=9.55x106xP
N
STEP2:Diameterofshaft,d=316Mt
s
STEP3:DesignofKey
a.) Lengthofkey=lengthofhub=l
b.) Widthofkey,b=2Mt
dlk
c.) Thicknessofkey,h=4Mt
dlb'

EXPERIMENT4
AIMDesignanddrawingofScrewJack
INTRODUCTION
Screwsusedforpowertransmissionareknownaspowerscrews.Theyprovidea
meansforobtainingalargemechanicaladvantage,insuchapplicationsasscrew
jacks,clamps,handpresseslandscrewonlathemachines,hoistingmachinesetc.
SCREWJACK

NOTATIONS
W=loadtobelifted
d=outsidediameterornominaldiameterofscrew
p=pitch
dh=diameterofhandle
lh=lengthofhandle
D=outsidediameterofnut
Di,Do=insideandoutsidethediameterofthrustcollar
dc=meandiameterofthethrustcollar=Di+Do
2
ln=nutlength
t=thicknessofbody
max=allowablenormalstressinthescrew
max=allowableshearstressinthescrew
b=allowablebendingstressinthescrew
b=allowablebearingpressureinthethreads
n=allowableshearstressinthenut
=coefficientofthreadfriction
c=coefficientofcollarfriction

DesignProcedure
STEP1:Designofscrew
a.) Consideringthescrewunderaxialcompression
c=W=>corearea,Ac=W
Acc
c=allowablecompressivestressinscrew=max

b.) Consideringthescrewasacolumnloadedinaxialcompression,whenfully
extended,Rankineequationforcolumns
=W1+ale2
Ack
=allowablestressinthescrew=max
Ac=d12/4
a=RankinesConstant=1/7500forsteels
le=equivalentlengthofthecolumn
ScrewJackisacolumnwithoneendfixedatnutandotherendisfreewherethe
loadissitting.
So,Equivalentlength,le=2x(liftorextension)
K=radiusofgyration=I=d14=d1
A644
d12

STEP2:Checkforprincipalstressesinthescrew
a.) Compressivestressinthescrew,c=W
Ac
b.) Shearstressinthescrew,s=Mtsr1
J
WhereMts=frictionaltorqueinthescrewonly

=Wd2tan+
21tan
d2=d1p,tan=l
2d2
(l=lead=1xpassumingsinglestart)
r1=d1
2
J=d14
32
c.) Combinedorprincipalstresses
i. Maximumnormalstress
max=1c+c2+4s2
2
ii. Maximumshearstress,max=1(c2+4s2)

2
STEP3:Designofscrewheadandcollar
Assumepinheaddiameter,Do=1.6d=outsidethediameterofthecollar
Pindiameter,Di=0.5d=Insidethediameterofthecollar
So,MeanDiameterofthecollar,dc=Di+Do
2

STEP4:Designofnut:
Assumingbronzefornut,
a.) Lengthofnut,ln=4Wp
b(d2d12)
b.) Tensilestressinthenut=nut=W
/4(D2d2)
Assume,b=15MPaand
nut=40to50MPa
STEP5:Frictionaltorque
TotalfrictionaltorqueincludingthecollarfrictionMt=Wd2tan++cdc
21tan2
STEP6:Designofhandle
a.) Lengthofhandle,lh=Mt
F
b.) Tofindthediameterofhandle,thehandleissubjectedtobendingmoment
WKTMb=b
Ic
WhereMb=bendingmoment=Flh=Mt

I=momentofinertiaforhandle,I=dh4

C=dh,b=allowablebendingstress

64


STEP7:Efficiency, =d2tan
tan+d2+cdc
1 tan
STEP8:Selflockingcondition
Thescrewjacktobeofselflockingtype,
Hencecheckforselflocking.
tan<d2+cdc
d2cdc

EXPERIMENT5
AIMDesignanddrawingofRivetedJoints
INTRODUCTION
Twoormoreplatesarejoinedbymeansofrivetsandsuchjointsarecalled
rivetedjoints.Thesejointsarepermanentinnatureunlikeboltedjoints.Theseare
usedinbridges,ships,boilers,tanks,etc.
RivetedJointsareclassifiedintotwotypesviz,lapjointandbuttjoint.

NOTATIONS
Pitch,p=Itisthedistancebetweencentresoftwoconsecutiverivetsinarow
Margin,m=Itisthedistancefromendofplatetofirstlowofrivets.
Transversepitch,pt=Distancebetweentwoconsecutiverowsofrivets.
Diagonalpitch,pd=Inzigzagriveting,thedistancebetweencentresofadjacent
rivetsinsidebysiderows
F=tensileorcompressiveloadonplates
d=diameteroftherivet
dh=diameterofrivethole
h=thicknessofmainplate
h1,h2=thicknessofcoverplates
i1=numberofrivetsinsingleshearinonepitchlengthorrepetitivelengthofjoint
i2=numberofrivetsindoubleshearinonepitchlength
C=Corrosionallowance1to3mm
K=factorasperboilercode
=efficiency
b=widthofplate
t==allowabletensilestressforplates
=allowableshearstressforrivets
c=allowablecrushingstressforrivets

RIVETEDJOINTSFORBOILERS
D1=Insidediameteroftheboiler
Pf=Fluidpressureorsteampressure
DESIGNPROCEDUREFORBOILERJOINTS
PartILongitudinaljoint
Step1:Thicknessofplateh=PfDi+C
2
=Efficiencyofjoint=0.7to0.8
C=Corrosionallowance=1to3mm
Step2:Diameteroftherivet,d=6h
Step3:Pitchoftherivets:
a.) p=(i1+1.875i2)d2+dhand
4ph
b.) p=Kh+40
Step4:Transversepitchpt=2.25d
Step5:Marginm=1.5d
Step6:Thicknessofcoverplates:
Forequalcoversh1=h2=0.625h
Forunequalcoversh1=0.625handh2=0.625h
Step7:Efficiency
a.) Efficiencyofplate,p=pd
P
b.) Efficiencyofrivetsinshear,=i1+1.875i2d2
4ph

c.) Efficiencyofrivetsincrushing,c=i2+i1h2c
h
i2+i1h2c+
h

PARTIICircumferentialjoints
Theplatestoberivetedbeingsameinbothlongitudinalandcircumferentialjoints
(hbeingsame),thediameterofrivets,transversepitchandmarginaresame.
h,d,ptandmaresameasabove.
Step1:TotalsteamloadF=Di2
4

STEP2:Strengthofeachrivet
a.) InshearF=d2
4
b.) IncrushingFc=dhc
STEP3:Numberofrivetsrequired=SteamLoad
Minimumstrengthofrivet

i=F
F1

Step4:Rivets/Rows=i/row=Totalnumberofrivets
Numberofrowsofrivets
Numberofrows=1forsinglerivetedjoint
=2fordoublerivetedjoint

Step5:Pitchforcircumferentialjoint
Pc=Circumference=Di
Rivets/Rowi/row
Step6:Efficiency
a.) Efficiencyofplate,p=pcdh
Pc
b.) Forrivetsinshear,=(i1+1.875i2)d2
4ph

c.) Forrivetsincrushing,c=i2+i1h2c
h
i2+i1h2c+
h