Faculty of Technology

Department of Mechanical Engineering

PREPARED BY: MACHINE ELEMENT II INSTRUCTORs

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 Chapter one
1. A hollow steel shaft transmits 600 kW at 500 r.p.m. The maximum shear stress is 62.4 MPa. Find the
outside and inside diameter of the shaft, if the outer diameter is twice of inside diameter, assuming that
the maximum torque is 20% greater than the mean torque.

2. A line shaft is to transmit 30 kW at 160 r.p.m. A motor placed directly under it by means drives it
of a belt running on a 1 m diameter pulley keyed to the end of the shaft. The tension in the tight side
of the belt is 2.5 times that in the slack side and the center of the pulley over-hangs 150 mm beyond
the center line of the end bearing. Determine the diameter of the shaft, if the allowable shear stress is
56 MPa and the pulley weighs 1600N.

3. A shaft made of 40 C 8 steel is used to drive a machine. It rotates at 1500 r.p.m. The pulleys A, B and
the bearings C, D are located as shown in Figure below. The belt tensions are also shown in the figure.

Figure 1
4. A solid steel shaft is supported on two bearings 1.8 m apart and rotates at 250 r.p.m. A 20° involute
gear D, 300 mm diameter is keyed to the shaft at a distance of 150 mm to the left on the right hand
bearing. Two pulleys B and C are located on the shaft at distances of 600 mm and 1350 mm
respectively to the right of the left hand bearing. The diameters of the pulleys B and C are 750 mm
and 600 mm respectively. 30 kW is supplied to the gear, out of which 18.75 kW is taken off at the
pulley C and 11.25 kW from pulley B. The drive from B is vertically downward while from C the
drive is downward at an angle of 60° to the horizontal. In both cases the belt tension ratio is 2 and the
angle of lap is 180°. The combined fatigue and shock factors for torsion and bending may be taken as
1.5 and 2 respectively. Design a suitable shaft taking working stress to be 42 MPa in shear and 84 MPa
in tension.

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5. A horizontal nickel steel shaft rests on two bearings, A at the left and B at the right end and carries
two gears C and D located at distances of 250 mm and 400 mm respectively from the center line of
the left and right bearings. The pitch diameter of the gear C is 600 mm and that of gear D is 200 mm.
The distance between the center lines of the bearings is 2400 mm. The shaft transmits 20 kW at 120
r.p.m. The power is delivered to the shaft at gear C and is taken out at gear D in such a manner that
the tooth pressure FtC of the gear C and FtD of the gear D act vertically downwards. Find the diameter
of the shaft, if the working stress is 100 MPa in tension and 56 MPa in shear. The gears C and D
weighs 950 N and 350 N respectively. The combined shock and fatigue factors for bending and torsion
may be taken as 1.5 and 1.2 respectively.

6. The layout of a shaft carrying two pulleys 1 and 2, and supported on two bearings A and B is shown
in Fig.2. The shaft transmits 7.5 kW power at 360 rpm from the pulley 1 to the pulley 2. The diameters
of pulleys 1 and 2 are 250 mm and 500 mm respectively. The masses of pulleys 1 and 2 are 10 kg and
30 kg respectively. The belt tensions act vertically downward and the ratio of belt tensions on the tight
side to slack side for each pulley is 2.5:1. The shaft is made of plain carbon steel 40C8 (Syt = 380
N/mm2) and the factor of safety is 3. Estimate suitable diameter of shaft. If the permissible angle of
twist is 0.5° per meter length, calculate the shaft diameter on the basis of torsional rigidity. Assume G
= 79300 N/mm2.

Figure 2
7. A line shaft supporting two pulleys A and B is shown in Figure.3.Power is supplied to the shaft by
means of a vertical belt on the pulley A, which is then transmitted to the pulley B carrying a horizontal
belt. The ratio of belt tension on tight and loose sides is 3:1. The limiting value of tension in the belts
is 2.7 kN. The shaft is made of plain carbon steel 40C8 (Sut = 650 N/mm2 and S yt = 380 N/mm2).
The pulleys are keyed to the shaft. Determine the diameter of the shaft according to the ASME code
if, kb= 1.5 and kt = 1.0.

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 Figure 3

8. The layout of an intermediate shaft of a gear box supporting two spur gears B and C is shown in Fig.3.
The shaft is mounted on two bearings A and D. The pitch circle diameters of gears B and C are 900
and 600 mm respectively. The material of the shaft is steel FeE 580 (Sut = 770 and Syt = 580 N/mm2).
The factors kb and kt of ASME code are 1.5 and 2.0 respectively. Determine the shaft diameter using
the ASME code. Assume that the gears are connected to the shaft by means of keys.

Figure 4

9. The engine of a ship develops 440 kW and transmits the power by a horizontal propeller shaft which
runs at 120 r.p.m. It is proposed to design a hollow propeller shaft with inner diameter as 0.6 of the
outer diameter. Considering torsion alone, calculate the diameter of the propeller shaft if stress in the
material is not to exceed 63 MPa and also the angular twist over a length of 2.5 m is not to be more
than 1°. The modulus of rigidity of the shaft material is 80 GPa.

10. The shaft of an axial flow rotary compressor is subjected to a maximum torque of 2000 N-m and a
maximum bending moment of 4000 N-m. The combined shock and fatigue factor in torsion is 1.5 and
that in bending is 2. Design the diameter of the shaft, if the shear stress in the shaft is 50 MPa. Design

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 a hollow shaft for the above compressor taking the ratio of outer diameter to the inner diameter as
2. What is the percentage saving in material? Also, compare the stiffness.

11. A shaft is supported by two bearings placed 1 m apart. A 600 mm diameter pulley is mounted at a
distance of 300 mm to the right of left hand bearing and this drives a pulley directly below it with the
help of belt having maximum tension of 2.25 kN. Another pulley 400 mm diameter is placed 200 mm
to the left of right hand bearing and is driven with the help of electric motor and belt, which is placed
horizontally to the right. The angle of contact for both the pulleys is 180° and μ = 0.24. Determine
the suitable diameter for a solid shaft, allowing working stress of 63 MPa in tension and 42 MPa in
shear for the material of shaft. Assume that the torque on one pulley is equal to that on the other
pulley.

12. A shaft made of steel receives 7.5 kW power at 1500 r.p.m. A pulley mounted on the shaft as shown
in Fig.6 has ratio of belt tensions 4.The gear forces are as follows :Ft = 1590 N; Fr = 580 N.

All dimensions are in mm

Figure 5

Design the shaft diameter by maximum shear stress theory. The shaft material has the following properties:
Ultimate tensile strength = 720 MPa; Yield strength = 380 MPa; Factor of safety = 1.5.

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 Chapter two
1. Design a compression coupling for a shaft to transmit 1300 N-m. The allowable shear stress for the shaft
and key is 40 MPa and the number of bolts connecting the two halves are 4. The permissible tensile stress
for the bolts material is 70 MPa. The coefficient of friction between the muff and the shaft surface may
be taken as 0.3.

2. It is required to design a rigid type of flange coupling to connect two shafts. The input shaft transmits
37.5 kW power at 180 rpm to the output shaft through the coupling. The service factor for the application
is 1.5, i.e., the design torque is 1.5 times of the rated torque. Select suitable materials for various parts of
the coupling, design the coupling and specify the dimensions of its components.

3. Design a shaft and flange for a Diesel engine in which protected type of flange coupling is to be adopted
for power transmission. The following data is available for design: Power of engine = 75 kW; speed of
engine = 200 r.p.m.; maximum permissible stress in shaft = 40MPa; maximum permissible twist in shaft
= 1° in length of shaft equal to 30 times the diameter of shaft; maximum torque = 1.25 × mean torque;
pitch circle diameter of bolts = 3 × diameter of shaft; maximum permissible stress in bolts = 20 MPa.
Find out : 1. Diameter of shaft, 2. number of bolts, and 3. diameter of bolts.

4. 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.

5. Design a single plate automobile clutch to transmit a maximum torque of 250 N-m at 2000 r.p.m. The
outside diameter of the clutch is 250 mm and the clutch is engaged at 55 km/h. Find: 1. the number of
revolutions of the clutch slip during engagement; and 2. heat to be dissipated by the clutch for each
engagement. The following additional data is available: Engine torque during engagement = 100 N-m;
Mass of the automobile = 1500 kg; Diameter of the automobile wheel = 0.7 m; Moment of inertia of
combined engine rotating parts, flywheel and input side of the clutch = 1 kg-m2; Gear reduction ratio at
differential = 5; Torque at rear wheels available for accelerating automobile = 175 N-m; Coefficient of
friction for the clutch material = 0.3; Permissible pressure = 0.13 N/mm2.

6. A plate clutch consists of one pair of contacting surfaces. The inner and outer diameters of the friction
disk are 100 and 200 mm respectively. The coefficient of friction is 0.2 and the permissible intensity of
pressure is 1 N/mm2. Calculate the power-transmitting capacity of the clutch at 750 rpm.
(i) Assuming the disk is brand new.
(ii) Assuming the disk is old.

7. A cone clutch with asbestos friction lining transmits 30 kW power at 500 rpm. The coefficient of friction
is 0.2 and the permissible intensity of pressure is 0.35 N/mm2. The semi-cone angle α is 12.5°. The outer
diameter is fixed as 300 mm from space limitations. Assuming uniform wear theory, calculate:
a. The inner diameter

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 b. The face width of the friction lining; and
c. The force required to engage the clutch

8. A soft surface cone clutch transmits a torque of 200 N-m at 1250 rpm. The larger diameter of the clutch
is 350 mm. The cone pitch angle is 7.5° and the face width is 65 mm. If the coefficient of friction is 0.2,
find :
i. The axial force required to transmit the torque;
ii. The axial force required to engage the clutch;
iii. The average normal pressure on the contact surfaces when the maximum torque is being
transmitted; and
iv. The maximum normal pressure assuming uniform wear.

9. A centrifugal clutch is to be designed to transmit 25 kW at 800 rpm. The shoes are six in number. The
speed at which the engagement begins is ¾th of the running speed. The inside radius of the pulley rim is
200 mm. The shoes are lined with Ferrodo for which the coefficient of friction may be taken as 0.3.
Determine:
a. Mass of the shoes, and
b. Size of the shoes.

10. A centrifugal clutch shown in the fig. consists of four shoes, each having a mass of 1.5 kg. In the engaged
position, the radius to the center of gravity of each shoe is 110 mm, while the inner radius of the drum is
140 mm. The coefficient of friction is0.3. The pre-load in the spring is adjusted in such a way that the
spring force at the beginning of engagement is 700 N. The running speed is 1440 rpm. Calculate:
a) The speed at which the engagement begins; and
b) The power transmitted by the clutch at 1440 rpm

Figure 6

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