Laboratory Man

FACULTY OF ENGINEERING AND

TECHNOLOGY
BACHELOR OF TECHNOLOGY

MACHINE DESIGN
(203109401)
SEMESTER : 7th

Laboratory Manual

PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
WAGHODIA,VADODARA
 PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design- (203109401) B. Tech. 4TH year

PREFACE

It gives us immense pleasure to present the first edition of Machine Drawing

Practical Book for the B.Tech. 4th year students for PARUL UNIVERSITY.
Machine Design-III laboratory courses at PARUL UNIVERSITY,
WAGHODIA, VADODARA are designed in such a way that students develop the
basic understanding of the subject in the laboratories and then try their hands on the
experiments/tutorials to realize the various physical phenomena learnt. The main
objective of the Machine Design laboratory course is: Learning mechanical
components and their practical problems. All the experiments are designed to serve
above objective and also to expose the students to various practical applications.

The objective of this Machine Design Practical Book is to provide a

comprehensive source for all the experiments included in the Machine Design
laboratory course. It explains all the aspects related to every experiment such as: basic
understanding of loads, stresses, components, Production Drawing, how to read
drawing and learn software to create such drawing.
We acknowledge the authors and publishers of all the books which we have
consulted while developing this Practical book. Hopefully this Machine Design
Practical Book will serve the purpose for which it has been developed.
 PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design- (203109401) B. Tech. 4TH year

Instructions to students
1. The main objective of the Machine drawing laboratory is: Learning about design of
various components & drawings & their failure criteria.
2. Be prompt in arriving to the laboratory and always come well prepared for the
experiment..
3. Work quietly on computers. Give equal opportunity to all your fellow students to
work.
4. Every student should have his/her individual copy of the Machine Design Practical
Book.
5. Every student have to prepare the notebooks specifically reserved for the Machine
drawing practical work:” Machine Design Practical Book”
6. Every student has to necessarily bring his/her Machine Design Practical Book,
Machine Design Practical notes and Machine Design Practical Final Notebook, when
he/she comes to the Computer centre..
7. Prepare your drawing honestly. Never makeup drawing or doctor them either to get a
better view & detail in drawing. Display all on print out of drawing (if applicable)
8. All the calculations have to be neatly recorded in the Machine Design Practical
Notebook and verified by the instructor before leaving the Computer center.
9. If some of the drawing doesn’t show appropriate detail then prepare drawing again or
modify it.
10. Do not share your drawings & calculations with your fellow student. Every student
has to produce his/her own set of drawings & calculations by performing exercise
separately.
11. After verification of the drawings & calculations, do the calculation in the Machine
Design Practical Notebooks and get them verified by the instructor.
12. Never forget to mention the units of the observed quantities in the calculation. After
calculations, represent the results with appropriate units.
13. Calculate the percentage error in the results obtained by you if the standard results are
available and also try to point out the sources of errors in the experiment.
14. Find the answers of all the questions mentioned under the section ‘Exercise’ at the
end of each experiment in the Machine Design Practical Book.
15. Finally record the verified observations along with the calculation and results in the
Machine Design Practical Notebook.
16. Do not forget to get the information of your next allotment (the experiment which is
to be performed by you in the next laboratory session) before leaving the laboratory
from the Technical Assistant.
17. Finally record the verified drawings & calculations along with all necessary details in
the Machine Design Practical Final Notebook.
18. The grades for the Machine Design practical course work will be awarded based on
your performance in the laboratory, regularity, recording of calculations in the
Machine drawing Practical Final Notebook, lab quiz, regular viva and end-term
examination.
 PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design- (203109401) B. Tech. 4TH year

CERTIFICATE

This is to certify that

Mr./Ms.........................................................................................................

..............with enrolment no. .........................................................................

has successfully completed his/her laboratory experiments in the Machine

Design (203109401) from the department of .................................

during the academic year........................s

Date of Submission:......................... Staff In charge:...........................

Head of Department:...........................................

INDEX
 PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design- (203109401) B. Tech. 4TH year

Sr. Hours Starting Completed Page

Experiment Name Marks Sign
No. date Date no.
1 Exercise based on various 2
terminologies related to gears, gear
boxes, Belt Drives, Bearings

2 Exercise to design spur gear and 2

helical gear

3 Exercise to design bevel gear, worm & 2

worm wheel

4 Exercise to design Gear Box. 2

5 Exercise to design belt and chain 2

drives.

6 Exercise to design Pulley and Wire 1

Rope

7 Exercise to design Roller Bearings. 1

8 Exercise to design Journal Bearings 1

9 Exercise based on drawing/ modelling 1

and analyse on designed component.
 PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design- (203109401) B. Tech. 4TH year

TUTORIAL NO :1
AIM- Exercise based on various terminologies related to gears, gear boxes, Belt Drives
and Bearings

(1) define the following :

(i) Cone distance; (ii) Pitch angle; (iii) Face angle; (iv) Root angle
(v) Back cone distance (vi) Crown height (vii) Interference (xi) Backlash

(2) Explain the effect of helix angle on power transmission capacity of helical gear. Also
suggest the values of helix angle for helical gear.

(3) What are the advantages of Belt Drive over Gear Drives. Derive an expression for
calculating the length of the Open belt drives and make suitable assumptions as per
requirements.

(4) What are the various forces acting on a bevel gear.

(5) Explain Geometric progression, Standard step ratio , Ray diagram.

(6) Write a Short note on classification of Bearings.

 PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design- (203109401) B. Tech. 4TH year

TUTORIAL NO :2

AIM: Exercise to design spur gear and helical gear

1) What are the advantages of helical gears over spur gears?

2) It is required to design a pair of spur gears with 20° full-depth involute teeth based on the
Lewis equation. The velocity factor is to be used to account for dynamic load. The pinion
shaft is connected to a 10 kW, 1440 rpm motor. The starting torque of the motor is 150% of
the rated torque. The speed reduction is 4 : 1. The pinion as well as the gear is made of plain
carbon steel 40C8 (Sut = 600 N/mm2). The factor of safety can be taken as 1.5. Design the
gears, specify their dimensions and suggest suitable surface hardness for the gears.

3) A pair of parallel helical gears consists of 24 teeth pinion rotating at 5000 rpm and
supplying 12 kW power to a gear. The speed reduction is 4:1 .The Normal Pressure angle
and helix angle are 200 and 230 respectively. Both gears are made of hardened steel (Sut=600
N/mm2).The service factor and factor of safety 1.5 and 3 respectively. Calculate

1. Module and face width of gears. 2. Surface hardness for the gears assuming a factor of
safety of 1.5 for wear consideration.

4) ) It is required to design a pair of spur gears with 20° full-depth involute teeth based on the
Lewis equation. The velocity factor is to be used to account for dynamic load. The pinion
shaft is connected to a ___ kW, 1440 rpm motor. The starting torque of the motor is ___% of
the rated torque. The speed reduction is ___. The pinion as well as the gear is made of plain
carbon steel 40C8 (Sut = ___ N/mm2). The factor of safety can be taken as 1.5. Design the
gears, specify their dimensions and suggest suitable surface hardness for the gears.

5) A pair of parallel helical gears consists of 24 teeth pinion rotating at 5000 rpm and
supplying ___ kW power to a gear. The speed reduction is ___.The Normal Pressure angle
and helix angle are 200 and 230 respectively. Both gears are made of hardened steel (Sut=___
N/mm2).The service factor and factor of safety 1.5 and 3 respectively. Calculate

1. Module and face width of gears. 2. Surface hardness for the gears assuming a factor of
safety of 1.5 for wear consideration.
 PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design- (203109401) B. Tech. 4TH year

TUTORIAL NO :3

AIM: Exercise to design Bevel gear, worm & worm wheel

1) What are advantages of straight bevel gear over spiral bevel gears? What is the relation
between actual and the pitch angle in the bevel gears?

2) A pair of bevel gears, with 20° pressure angle, consists of a 20 teeth pinion meshing with
a 30 teeth gear. The module is 4 mm, while the face width is 20 mm. The material for pinion
and gear is steel 50C4 (Sut = 750 N/mm2). The gear teeth are lapped and ground (Class-3)
and the surface hardness is 400 BHN. The pinion rotates at 500 rpm and receives 2.5 kW
power from the electric motor. The starting torque of the motor is 150% of the rated torque.
Determine the factor of safety against bending failure and against pitting failure.
3) A pair of worm and worm wheel is designated as, 1/30/10/10
The input speed of the worm is 1200 rpm. The worm wheel is made of centrifugally cast,
phosphor bronze and the worm is made of case-hardened carbon steel 14C6. Determine the
power transmitting capacity based on the beam strength

4) A pair of bevel gears, with 20° pressure angle, consists of a ___ teeth pinion meshing with
a ___ teeth gear. The module is 4 mm, while the face width is 20 mm. The material for
pinion and gear is steel 50C4 (Sut = ___ N/mm2). The gear teeth are lapped and ground
(Class-3) and the surface hardness is 400 BHN. The pinion rotates at 500 rpm and receives
___kW power from the electric motor. The starting torque of the motor is 150% of the rated
torque. Determine the factor of safety against bending failure and against pitting failure.

5) A pair of worm and worm wheel is designated as, _________

The input speed of the worm is ___ rpm. The worm wheel is made of centrifugally cast,
phosphor bronze and the worm is made of case-hardened carbon steel 14C6. Determine the
power transmitting capacity based on the beam strength
 PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design- (203109401) B. Tech. 4TH year

TUTORIAL NO : 4

AIM: Design of Gear Box

1) Explain design procedure for 6 speed reduction gear box.

2) A three stage gear box with twelve speeds is to be designed based on R10 series with
minimum spindle speed of 125 rpm. The second stage consists of three speed steps. The
electric motor is connected to the gear box through a belt drive and runs at 1440 rpm and
transmits of 5 kW. Using standard spindle speeds,
1. Draw the structure and speed diagram for the arrangement.
2. Determine the ratio of the belt pulley diameters.
3. Draw the gear box layout.
4. Determine the number of teeth on each gear of the gear box.

Draw speed ray diagram and layout for a six speed gear box .The output speed are 160 r.p.m.
Minimum and 1000 r.p.m. Maximum. The motor speed is 1440 r.p.m.

3) Design a suitable speed gear box for a head stock of a lathe that has a variation of speed
from 105 r.p.m. to 690 r.p.m. in 9 steps. The power is supplied by an electric motor of 10
KW capacity running at 1000 r.p.m. and having driving the input shaft through a V-belt drive
having speed ratio of 2: 1. Draw the structural diagram, speed chart and determine the
number of teeth on each gears.
 PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design- (203109401) B. Tech. 4TH year

TUTORIAL NO: 5

AIM: - Study Design of belt drives.

1) Explain Slip & creep of belt.

2) Explain Belt materials in detail.

3) Write down procedure for selection of chain drive

4) Design a flat belt drive to transmit 110 kW at a belt speed of 25 m/s between two pulleys of
diameters 250 mm and 400 mm having a pulley centre distance of 1 meter. The allowable
belt stress is 8.5 Mpa and the belts are available having a thickness to width ratio of 0.1 and
a material density of 1100 kg/m3. Given that the coefficient of friction between the belt and
pulleys is 0.3, determine the minimum required belt width. What would be the necessary
installation force between the pulley bearings and what will be the force between the pulley
bearings when the full power is transmitted?

5) A 18 kW, 900 r.p.m. motor drives a centrifugal pump at 290 r.p.m. by means of a
leather belt. The pulleys are of cast iron and are 1.2 meter centre distance. The
pulleys of diameter less than 150 mm should not be used. The coefficient of friction
between the leather belt and the cast iron pulley is 0.35, and the mass of the belt is 9
kg/m width/m length. The maximum permissible tension per mm width of the belt is
10 N. The drive is to be designed for 20% overload. Determine the pulley diameters,
the required width and length of the belt. Also find the initial tension with which the
belt is to be mounted on the pulleys.
 PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design- (203109401) B. Tech. 4TH year

TUTORIAL NO: 6
AIM: Exercise to design Pulley and Wire Rope
1 Discuss the different types of pulleys used in belt drives.

2. Discuss the procedure used in designing a cast iron pulley.

3. Discuss the uses and construction of wire ropes. How are wire-rope ends fastened
4. A cast iron pulley transmits 20 kW at 300 r.p.m. The diameter of pulley is 550 mm and
has four straight arms of elliptical cross-section in which the major axis is twice the
minor axis. Find the dimensions of the arm if the allowable bending stress is 15 Mpa.
Mention the plane in which the major axis of the arm should lie.

5. A workshop crane is lifting a load of 25 KN through a wire rope and a hook. The
weight of the hook etc. is 15 KN. The rope drum diameter may be taken as 30 times the
diameter of the rope. The load is to be lifted with an acceleration of 1 m/s2. Calculate the
diameter of the wire rope. Take a factor of safety of 6 and Young’s modulus for the wire
rope 80 kN/mm2. The ultimate stress may be taken as 1800 Mpa. The cross-sectional
area of the wire rope may be taken as 0.38 times the square of the wire rope diameter
 PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design- (203109401) B. Tech. 4TH year

TUTORIAL NO: 7

AIM: Exercise to design Roller Bearing.

1. Write short note on classifications and different types of antifriction bearings.

2. How do you express the life of a bearing? What is an average or median life?

3. Define the following terms as applied to rolling contact bearings:

(a) Basic static load rating (b) Static equivalent load
(c) Basic dynamic load rating (d) Dynamic equivalent load

3. A single row angular contact ball bearing number 310 is used for an axial flow
compressor. The bearing is to carry a radial load of 2500 N and an axial or thrust load
of 1500 N. Assuming light shock load, determine the rating life of the bearing

4. Design a self-aligning ball bearing for a radial load of 7000 N and a thrust load of 2100
N. The desired life of the bearing is 160 millions of revolutions at 300 r.p.m. Assume
uniform and steady load,
 PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design (03109401) B. Tech. 4TH year

TUTORIAL NO: 8

AIM: Exercise to design Journal Bearing.

1. What are journal bearings? Give a classification of these bearings.

2. What is meant by hydrodynamic lubrication?

3. List the basic assumptions used in the theory of hydrodynamic lubrication

4. Design a journal bearing for a centrifugal pump from the following data :
Load on the journal = 20 000 N; Speed of the journal = 900 r.p.m.; Type of oil is SAE 10,
for which the absolute viscosity at 55°C = 0.017 kg / m-s; Ambient temperature of oil =
15.5°C; Maximum bearing pressure for the pump = 1.5 N / mm2.
Calculate also mass of the lubricating oil required for artificial cooling, if rise of
temperature of oil be limited to 10°C. Heat dissipation coefficient = 1232 W/m2/°C.

5. The load on the journal bearing is 150 kN due to turbine shaft of 300 mm diameter running
at 1800 r.p.m. Determine the following: (1) Length of the bearing if the allowable bearing
pressure is 1.6 N/mm2 (2) Amount of heat to be removed by the lubricant per minute if the
bearing temperature is 60°C and viscosity of the oil at 60°C is 0.02 kg/m-s and the bearing
clearance is 0.25 mm.

DEPARTMENT OF MECHANICAL ENGINEERING Page 13

 PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design (03109401) B. Tech. 4TH year

TUTORIAL NO: 9
AIM: Exercise based on drawing/ modeling and analyze on designed component.

1. Create component models for fixture assembly (Fig.1) which consists of various parts like
end plate, disc, support pin, nut, bolt, spacer, centre pin. The dimensions of these parts are
given in following figures.

Fig. 2 Dimensions of the end plate

DEPARTMENT OF MECHANICAL ENGINEERING Page 14

 PARUL UNIVERSITY
FACULTY OF ENGINEERING AND TECHNOLGOY
Machine Design (03109401) B. Tech. 4TH year

Fig. 4 Dimensions of the support pin

Fig. 5 Dimensions of the bolt

Fig. 6 Dimensions of Spacer, Centre pin and Nut

Exercise:

1. To assemble the Solid models which is prepared in Practical 5 for fixture assembly? Take
the details of all parts from the previous practical and assemble all parts.

DEPARTMENT OF MECHANICAL ENGINEERING Page 15