MACHINE DESIGN AND INDUSTRIAL DRAFTING

MARWADI EDUCATION FOUNDATIONS GROUP OF INSTITUTIONS

FACULTY OF ENGINEERING, GAURIDAD CAMPUS.
DEPARTMENT OF MECHANICAL ENGINEERING

Machine Design and Industrial Drafting

Laboratory Manual

Name of Faculty : ____________________________

Semester

: ____________________________

Branch

: ____________________________

MACHINE DESIGN AND INDUSTRIAL DRAFTING

INDEX
Dates

Sr.

Grades/

Term Work
No.
1

Solve problems related to Eccentric Loading;

Cotter and Knuckle Joints

Design and Analysis of Levers: Cranked, Bell

Crank, Foot, Rocker arm. Also prepare 3D
models and detailed drawings of Cotter and
Knuckle Joints.

Case studied for design and analyze component

which can be idealized as beams and columns.

End

Remarks

Design of shafts, keys and Couplings.

Problems for design of joints using welding,

riveting and fasteners. Design of Screw jack and
Toggle jack
Problems related to Limits, fits and tolerances.

Introduction to computer aided drafting tools.

Using drafting software, generate Assembly and

Production drawings (emphasis should be to
demonstrate guidelines of IS SP 46 2003).

Sign.
Start

Lab In-charge

H.O.D. (Mechanical)

MACHINE DESIGN AND INDUSTRIAL DRAFTING

LIST OF EXPERIMENTS
1

2
3
4
5
6
7
8

Solve problems related to Eccentric Loading; Cotter and Knuckle Joints

Design and Analysis of Levers: Cranked, Bell Crank, Foot, Rocker arm. Also prepare 3D
models and detailed drawings of Cotter and Knuckle Joints.
Case studied for design and analyze component which can be idealized as beams and
columns.
Design of shafts, keys and Couplings.
Problems for design of joints using welding, riveting and fasteners. Design of Screw jack
and Toggle jack.
Problems related to Limits, fits and tolerances.
Introduction to computer aided drafting tools.
Using drafting software, generate Assembly and Production drawings (emphasis should
be to demonstrate guidelines of IS SP 46 2003).

OPEN ENDED PROBLEMS:

1. Design / Analyze a mechanical structure which may involve different components included
in syllabus. Prepare assembly and production drawings.

2. Design a shipping container.

MACHINE DESIGN AND INDUSTRIAL DRAFTING

EXPERIMENT: 1

Date: - / /

AIM: To study about eccentric loading, cotter - knuckle joints and levers.
INTRODUCTION:
An external load, whose line of action is parallel but does not coincide with the
centroidal axis of the machine component, is known as an eccentric load. The distance
between the centroidal axis of the machine component and the eccentric load is called
eccentricity and is generally denoted by e. The examples of eccentric loading, from the
subject point of view, are C-clamps, punching machines, brackets, offset connecting
links etc.

Design Problems
1. A c frame of the press takes a load of 100 kN at an eccentricity of 250mm. calculate the
cross-sectional dimensions of the frame, considering the section of frame I- section
with thickness of web and flange being t, depth 6t and width 3t. the material of the
frame has permissible tensile stress is 100MPa.

2.

An offset link has a clear swing of 10 mm. the radius of curvature of curved part is more
compare to swing of link. The cross section is shown, where the thickness (t) of link is
26 mm. Find the load corresponding to a maximum fiber stress of 100 N/mm2.

3. It is required to design a cotter joint to connect two steel rods of equal diameter.
a. The permissible stresses for the rods, spigot end and socket end are t
=96 N/mm2, c = 134 N/mm2 & = 45 N/mm2. For cotter, t =80 N/mm2 , =
40 N/mm2. Each rod is subjected to an axial Tensile force of 60 KN. Calculate
following dimensions:
b . diameter of spigot

MACHINE DESIGN AND INDUSTRIAL DRAFTING

c. width & thickness of cotter

d. thickness of socket collar
4. Design a socket and spigot joint to resist a tensile load of 28 KN. All the parts of the
joint are made from same material with following allowable stresses:

5. Design a knuckle joint to connect two mild steel bars under a tensile load of 35kN. The
allowable stresses are 75 MPa in tension, 60 MPa in shear and 83 MPa in crushing.
Standard diameter of solid bars are 20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40 mm.
Check failure of knuckle pin in shear, failure of rod end & forked end in tension, shearing
and crushing.

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EXPERIMENT: 2

Date: - / /

AIM: Design and Analysis of Levers: Cranked, Bell Crank, Foot, Rocker arm
INTRODUCTION:

A lever is a rigid rod or bar capable of turning about a fixed point called fulcrum. It is
used as a machine to lift a load by the application of a small effort. The ratio of load lifted
to the effort applied is called mechanical advantage. Sometimes, a lever is merely used
to facilitate the application of force in a desired direction. A lever may be straight or curved
and the forces applied on the lever (or by the lever) may be parallel or inclined to one
another. The principle on which the lever works is same as that of moments.

Design Problems
1

The lever of a lever loaded safety valve shown in Fig. The diameter of the valve is 80 mm
and valve has to blow off at a pressure of 1.25 MPa. The permissible stress in
tension, shear and crushing are 70 MPa, 20 MPa and 50 MPa respectively. The
permissible bearing pressure for the pin may be taken as 20 MPa. Design the pins
and the lever; assume rectangular cross section of the lever with height equal to three
times the thickness.

Design a rocker arm lever having equal arms of 160 mm length inclined at 1350 for an
exhaust valve of a gas engine subjected to a maximum force of 2500 N at roller end.
Consider I cross section 6t x 2.5t x t size (where t = thickness of web and flange) for
lever. The permissible stresses for the lever material are 80MPa in tension and design
bearing pressure is 6 MPa for pin.

A right angle bell crank lever is shown in Fig-4. The load W = 4.5KN. The lever
consists of forged steel material and a pin at the fulcrum. Take the following
permissible stress for the pin and lever material. Safe stress in tension = 75MPa, Safe
stress in shear = 60MPa, Safe bearing pressure on pin = 10N/mm2. The length of

MACHINE DESIGN AND INDUSTRIAL DRAFTING

fulcrum pin is 1.25 times the diameter of fulcrum pin. Calculate the following.
1. Reaction at fulcrum pin
2. Fulcrum pin dimensions
3. Lever dimensions

4.
A foot lever is 1 m from the centre of shaft to the point of application of 800 N
load. Find: 1. Diameter of the shaft, 2. Dimensions of the key, and 3. Dimensions of
rectangular arm of the foot lever at 60 mm from the centre of shaft assuming width of the
arm as 3 times thickness. The allowable tensile stress may be taken as 73 MPa and
allowable shear stress as 70 MPa.
5

A cranked lever, as shown in Fig., has the following dimensions :

Length of the handle = 300 mm
Length of the lever arm = 400 mm
Overhang of the journal = 100 mm
If the lever is operated by a single person exerting a maximum force of 400 N at a
distance of 1/3 rd length of the handle from its free end, find : 1. Diameter of the
handle, 2. Cross-section of the lever arm, and 3. Diameter of the journal.
The permissible bending stress for the lever material may be taken as 50 MPa and
shear stressfor shaft material as 40 MPa.

MACHINE DESIGN AND INDUSTRIAL DRAFTING

EXPERIMENT: 3

Date: - / /

AIM: To study about design and analyses of structures or components, which

can be idealized as beams and columns.
INTRODUCTION:
A machine part subjected to an axial compressive force is called a strut. A
strut may be horizontal, inclined or even vertical. But a vertical strut is known as a
column, pillar or stanchion. The machine members that must be investigated for
column action are piston rods, valve push rods, connecting rods, screw jack, side
links of toggle jack etc. In this chapter, we shall discuss the design of piston rods,
valve push rods and connecting rods. A machine parts which is subjected to load
transverse or perpendicular to axis of the component can be treated as Beam and
analyze such a component using Beam Theory.

Design Problems

A transmission shaft with a uniformly distributed load of 10 N/mm is shown in

figure. The maximum permissible deflection of shaft is 0.003L, where L is the
span length. The modulus of elasticity of shaft material is 207000 N/mm2.
Determine the shaft determine by castiglianos theorem.

Calculate the diameter of a piston rod for a cylinder of 1.5 m diameter in which
the greatest difference of steam pressure on two sides of the piston may be
assumed to be 0.2 N/mm2. The rod is made of mild steel and is secured to the
piston by a tapered rod and nut and to the crosshead by a cotter. Assume modulus

MACHINE DESIGN AND INDUSTRIAL DRAFTING

of elasticity as 200 KN/mm2 and factor of safety as 8. The length of rod may be
assumed as 3 metres.

The connecting rod of a steam locomotive is circular in cross-section with a

diameter 0.075m. The length of rod is 1.5 m. The ends of the rod may be assumed
to be pin jointed. Take the safe stress for the material in compression as 63
MN/m2. Elastic limit as 280 MN/m2 and modulus of elasticity as 210 GN/m2.
Determine the safe load for the rod.

A cast iron pulley transmits 10 KW at 400 r.p.m. The diameter of pulley is 1.2
metre and it has four straight arms of elliptical cross-section, in which the major
axis is twice the minor axis. Determine the dimensions of the arm if the allowable
bending stress is 15 Mpa.

Determine the dimensions of an I-section connecting rod for an internal

combustion engine having the following specifications:
Diameter of the piston
= 120 mm
Mass of reciprocating parts
= 350 kg/m2 of piston area
Length of connecting rod
= 350 mm
Engine revolutions per minute
= 1800
Maximum explosion pressure
= 3 N/mm2
Stroke length
= 180 mm
The flange width and depth of the I-section rod are in the ratio of 4t:6t where t
is the thickness of flange and web. Assume yield stress in compression for the
material as 330 MPa and a factor of safety as 6.

Determine the diameter of push rod made of mild steel of an I.C engine if the
maximum force exerted by push rod is 1500 N. The of push rod is 0.5 m. Take the
factor of safety as 2.5 and the end fixity coefficient as 2.

A beam of I-section 500 mm deep and 200 mm wide has flanges 25mm thick and
web 15mm thick as shown in figure. It carries a shearing force of 400 KN. Find
the maximum intensity of shear stress in the section, assuming the moment of
inertia to be 645 x 10^6 mm4. Also find the shear stress at the joint and at the
junction of top of the web and the bottom of flange.

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MACHINE DESIGN AND INDUSTRIAL DRAFTING

EXPERIMENT: 4

Date: - /

AIM: To study about design of shafts, keys and couplings.

INTRODUCTION:
A shaft is a rotating machine element which is used to transmit power from one
place to another. The power is delivered to the shaft by some tangential force and the
resultant torque (or twisting moment) set up within the shaft permits the power to be
transferred to various machines linked up to the shaft. In order to transfer the power
from one shaft to another, the various members such as pulleys, gears etc., are
mounted on it. These members along with the forces exerted upon them causes the
shaft to bending. In other words, we may say that a shaft is used for the transmission
of torque and bending moment. The various members are mounted on the shaft by
means of keys or splines.
A key is a piece of mild steel inserted between the shaft and hub or boss of the
pulley to connect these together in order to prevent relative motion between them. It
is always inserted parallel to the axis of the shaft. Keys are used as temporary
fastenings and are subjected to considerable crushing and shearing stresses. A keyway
is a slot or recess in a shaft and hub of the pulley to accommodate a key.

Design Problems

1. Determine the diameter below which the angle of twist of a shaft and not the
maximum stress, is the controlling factor in design of solid shaft in torsion. The
allowable shear stress is 56 MPa and the maximum allowable twist is degree per
meter. Take G = 84 MPa.
2. Compare the weight, strength and rigidity of a hollow shaft of same external
diameter as that of solid shafts, both the shafts are made of same material.
Assume that diameter ratio for the hollow shaft is di/do = 0.6
3. A shaft transmits 75 kw power at 300 rpm load is gradually applied. It is also
subjected to B.M. of 500 N-M, shear stress in shaft material should not exceed 40
N/mm2. Shaft must not twist more than 2o per meter length. Modulus of rigidity of
shaft material is 0.8105 N/mm2. Find the diameter of solid shaft. If the shaft is
chosen is hollow with inside to outside diameter ratio = 0.5, Find the size of the
hollow shaft. What is the percentage saving in material by using hollow shaft
instead of solid shaft?

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MACHINE DESIGN AND INDUSTRIAL DRAFTING

4. A horizontal shaft AD supported in bearings at A and B and carrying pulleys at C
and D is to transmit 75 kW at 500 r.p.m. from drive pulley D to pulley C, as
shown in Fig. Calculate the diameter of shaft. The data given is: P1 = 2 P2 (both
horizontal), Q1 = 2 Q2 (both vertical), radius of pulley C = 220 mm, radius of pulley
D = 160 mm, allowable shear stress = 45 MPa.

5. Design a muff coupling to transmit 30KW at 100RPM. The allowable shear stress
for the shaft and key is 40MPa and the number of bolts connecting the two halves
are 6. The permissible tensile stress for the bolts is 70MPa. The coefficient of
friction between the muff and the shaft surface may be taken as 0.3. Take width
of key = Shaft diameter/4 and thickness of key = Shaft diameter/6
6. Design a clamp coupling to transmit 30 kW at 100 r.p.m. The allowable shear stress
for the shaft and key is 40 MPa and the number of bolts connecting the two halves
are six. The permissible tensile stress for the bolts is 70 MPa. The coefficient of
friction between the muff and the shaft surface may be taken as 0.3.
7. Design a bush pin type protected flexible flange coupling to connect the output
shaft of an electric motor to the shaft of a centrifugal pump. The motor delivers
20 kW power at 720 r.p.m. The starting torque of motor can be assumed to be
150 % of the rated torque. The permissible stresses are as under : 95MPa in shear
for shaft, 100MPa in shear and 300MPa in crushing for key, 200MPa in tension
and 35MPa in shear for pin and 17MPa in shear for flanges. Consider the No. of
pins = 6
8. Design a cast iron protective type flange coupling to transmit 15 kW at 900
r.p.m. from an electric motor to a compressor. The service factor may be
assumed as 1.70. The following permissible stresses may be used: Shear stress for
shaft, bolt and key material = 40 MPa Crushing stress for bolt and key = 80 MPa Shear
stress for cast iron = 8 MPa Standard shaft diameter: 20, 22, 24, 26, 28, 30, 32, 34,
36, 38, 40 mm. Take number of bolts are 3.

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MACHINE DESIGN AND INDUSTRIAL DRAFTING

9. Design a cast iron flange coupling for a mild steel shaft transmitting 90KW at
250RPM. The allowable shear stress in the shaft is 40MPa and the angle of twist
is not to exceed 1 degree in a length of 20 diameters. The allowable shear stress in
the coupling bolts is 30MPa. Take width of key = Shaft diameter/4 and thickness
of key = Shaft diameter/6. Assume number of bolts = 4

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MACHINE DESIGN AND INDUSTRIAL DRAFTING

EXPERIMENT: 5

Date: - /

AIM: Design of joints using welding, riveting and fasteners. Design of screw jack
and toggle jack.
INTRODUCTION:
A welded joint is a permanent joint which is obtained by the fusion of the edges
of the two parts to be joined together, with or without the application of pressure and
a filler material. The heat required for the fusion of the material may be obtained by
burning of gas (in case of gas welding) or by an electric arc (in case of electric arc
welding). The latter method is extensively used because of greater speed of welding.
A rivet is a short cylindrical bar with a head integral to it. The rivets are used to
make permanent fastening between the plates such as in structural work, ship
building, bridges, tanks and boiler shells. The riveted joints are widely used for
joining light metals.

Design Problems

1. A welded connection of steel plates, as shown in figure is subjected to an eccentric

force of 10 KN. Determine the throat dimension of welds, if permissible shear stress
is limited to 95 Mpa. Assume static condition.

2. A circular shaft, 75 mm diameter is welded to the support by means of

circumferential fillet weld. It is subjected to a torsional moment of 3000 N-m.
Determine size of weld, if the maximum shear stress in the weld is not exceed 70
Mpa.
3. A double riveted double strap butt joint is used to connect two plates, each of 12 mm
thickness, by means of 16 mm diameter rivets having a pitch of 48 mm. The rivets

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MACHINE DESIGN AND INDUSTRIAL DRAFTING

and plates are made of steel. The permissible stress in tension, shear and compression
are 80, 60 and 120 Mpa respectively. Determine efficiency of joint.
4. A cylindrical pressure vessel with 0.8 m inner diameter is subjected to an internal
steam pressure of 2 Mpa. The permissible stresses for cylinder plate and rivets in
tension, shear and compression are 80, 60 and 120 Mpa respectively. The efficiency
of longitudinal joint can be taken as 80% for the purpose of calculating the plate
thickness. The corrosion allowance is 2 mm. The efficiency of circumferential lap
joint should be at least 62%. Design circumferential lap joint and calculate:
(a) Thickness of the plate
(b) Diameter of rivets
(c) Number of rivets
(d) Number of rows of rivets
(e) Pitch of the rivets
(f) Overlap of the plates.
5. Design and draw screw jack for lifting a safe load of 150 KN through a maximum lift
of 350 mm. The elastic strength of material of screw may be taken as 240 Mpa in
compression and 160 Mpa in shear. The nut is to be made of phosphor bronze for
which the elastic strength in tension, compression and shear are respectively 130, 115
and 100 Mpa. Bearing pressure between the threads of screw and nut may be taken as
18 Mpa. Safe crushing stress for the material of body is 100 Mpa. Coefficient of
friction for screw as well as collar may be taken as 0.15.
6. Design a toggle jack to lift a load of 5 KN. The jack is to be so designed that the
distance between the centre lines of nuts varies from 50 to 220 mm. The eight links
are symmetrical and 120 mm long. The link pins in the base are set 30 mm apart. The
links, screw and pins are made from mild steel for which the stresses are 90 Mpa in
tension and 50 Mpa in shear. The bearing pressure on pin is 20 Mpa. Assume the
coefficient of friction between screw and nut as 0.15 and pitch of the square threaded
screw as 6 mm.

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MACHINE DESIGN AND INDUSTRIAL DRAFTING

EXPERIMENT: 6

Date: - /

AIM: To study about limits, fits and tolerances.

INTRODUCTION:
The term interchangeability is normally employed for the mass production o
indentical items within the prescribed limits of sizes. A little consideration will show
that in order to maintain the sizes of the part within a close degree of accuracy, a lot
of time is required. But even then there will be small variations. If the variations are
within certain limits, all parts of equivalent size will be equally fit for operating in
machines and mechanisms. Therefore, certain variations are recognized and allowed
in the sizes of the mating parts to give the required fitting. This facilitates to select at
random from a large number of parts for an assembly and results in a considerable
saving in the cost of production. In order to control the size of finished part, with due
allowance for error, for interchangeable parts is called limit system.

Design Problems

1. Calculate the fundamental tolerance for a shaft of 90 mm and grade 10. Use
geometrical mean D=100 mm and following table:
Grade

IT7

IT8

IT9

IT10

IT11

IT12

Tolerance Value

16i

25i

40i

64i

100i

160i

2. Give the dimensions for the hole and shaft for the following:
(a) A 12 mm electric motor sleeve bearing;
(b) A medium force fit on a 200 mm shaft; and
(c) A 50 mm sleeve bearing on the elevating mechanism of a road grader.
3. Calculate the tolerances, fundamental deviations and limits of sizes for the shaft
designated as 40 H8 / f7.
4. A medium force fit on a 75 mm shaft requires a hole tolerance and shaft tolerance
each equal to 0.225 mm and average interference of 0.0375 mm. Find the hole and
shaft dimensions.

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MACHINE DESIGN AND INDUSTRIAL DRAFTING

5. A journal of basic size of 75 mm rotates in a bearing. The tolerance for both the shaft
and bearing is 0.075 mm and the required allowance is 0.10 mm. Find the dimensions
of the shaft and the bearing bore.
6.

Find the extreme diameters of shaft and hole for a transition fit H7/n6, if the nominal
or basic diameter is 12 mm. What is the value of clearance and interference?

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MACHINE DESIGN AND INDUSTRIAL DRAFTING

EXPERIMENT: 7

Date: - /

AIM: Introduction to computer aided drafting tools.

Introduction to Drafting.
Differentiate Design and Drafting.
Name of Software available in market used for Drafting.
Different Co-ordinate system for drafting tool.

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MACHINE DESIGN AND INDUSTRIAL DRAFTING

EXPERIMENT: 8

Date: - /

AIM: To draft assembly and detailed drawings using a drafting software

A. Basic Drawing:

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B. Component Assembly and Detailed Drawing:

1. Design and draw a cotter joint to support a load varying from 30 kN in

compression to 30 kN in tension. The material used is carbon steel for which the
following allowable stresses may be used. The load is applied statically. Tensile
stress = compressive stress = 50 MPa ; shear stress = 35 MPa and crushing stress
= 90 MPa.

2. Design and draw a knuckle joint to transmit 150 kN. The design stresses may be
taken as 75 MPa in tension, 60 MPa in shear and 150 MPa in compression.

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Note: Draw Assembly and detailed drawing of above component by drafting tool using specific
dimensions.

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