Off: 22357273,22357274

ANNA UNIVERSITY Dir:

Fax:
22357275,22357276
91-44-22301134
CHENNAI 600 025 Emal: coe@annauniv.edu
OFFICE OF THE CONTROLLER OF EXAMINATIONS

Letter No.24100/UG/C10/2015 Dated: 31/08/2015

From To
Dr.G.V.UMA The Principals of all Affiliated College/
Controller of Examinations Government College / Deans of University
Anna University Colleges under Anna University,
Chennai — 600 025 Chennai — 600 025 (Zone I to XXI)

Sir,

Sub: O/o COE Anna University, Chennai — 25 — Theory Examinations — Affiliated

Colleges — Nov/Dec 2015 Exams — Permission to use the Code books for ME6503,
Regulation 2013 — Reg.

The principals of all the affiliated colleges, offering

B.E Mechanical

Engineering is informed that the Approved Additional Pages are also permitted along with the PSG

Design Data Book in the Examination ‘ME6503 - Design of Machine Elements’

Yours faithfull ,

‘CONTROLLERWF EXAMINATIONS
Encl: As above
Copy to All the Zonal Co-ordinator
Zonel to 21
PSG DESIGN DATA BOOK

ADDITIONAL PAGES
 Phone:22351126, 351723,2235132.-
c«: ,*no. r» ›.cG1357
Smai!’. ramaiyan!{ •nnauni›'.edu

Lr.No. 53 "2/AC21/2G.33 25 Se tember,20

The Direc or,

Acad•mic Courses
Anna Un-i ersity
Chennai-2 ,.

fi
In : tie curriculum of B.E. Mechanical Engin.eerinp•, there is a course or “lvi.E. 331
Design ’Machine Elements”. The PSG D.‹sign Data Book is an approved I:ie date book
which is permitted in he examination. Hc•wever the Principal, Sri Krishn: College of
Engineering and Technqolog3•, Coimbatore h:is stated that data are not availabi e. for certain
items like Design of P:•pe Joints, Dqsign of Piston Assembly, Design of shai:t couplings or.d
has sent data including figures for use in tire examination. The sanie‘ has been scrutinized by
me and found to be in ord•r.

The Principal of all affiliated colleges, o&ering B.E. Mechanical Engii:eering may
please be foüned tJiät the additioiial pages (copy to be sentj‘ enclosed are also permitted
along with the PSG Design Data Book ir. the Examination on “Design- v›f machine
Elements”.

sd/-
Cîhe.irman
Faculty of Mechanical Engin-
ering

ANN 4
ILN'IVERSITà’:CHEhNAI 600 IJ25
Academic Courses
Date:
z5.99.2003
DI OR
Copy for›væ ded îoJ‘ info riuation and nec•ssai¿' action (Acade
To
B.11 Principale o£iering i3.E. .Llechariical Engineering
 CONTENTS

1. III 'Sl t3N OF PII'E JOIN’I“S

1.l Cii’crilai’ Flaiiged Pipe Joint l

I .2 Oval ñlaiigeJ Fipe Joint

I .3 SÇri2re Plangecl Pipe Jciizt

2. Î9f',SÎCN OF Pf STON ASSF.MBl.Y

1. Design of Cylinder
2. Design of Piston
3. I9esign of Pistc•n Rings
4. I'iston Oat i el
2.? Piston Skii‘t
' 2.b Pipi . -
9

3. DESltîN OF iIIAr’'“ Ü«›'r!!NGS i?

12
I
ñ
l
2
 List of Figures

1. Circular Flanged Pipe Joint 3

2. Oval Flanged Pipe Joint 4

3. Square Flanged Pipe Joint §

2. I Piston for IC Engines 10
2.2 Piston Pin I
4. Sleeve or Muff Coupling i
5. Unprotected Type flange Coupling 14

2. ProteGtive Type Flange Coupling 11

3. Bushed — Pin Flexible Coupling i

4. Marine Type Flange Coupling
«
17
18
 1. D “SIGN OF PIPE JOINJ“S

Di = 1.8.8 W/vp
Di — Internal diameter ‹if pipe

Tonnes /h:‘ for Liqti.cis

p- Dec› ity in Kg/m' for gases o d Tonne/m
for liquid.
v — Flo'-v x'elocity m/s.
1.1 Circular Flanged pipe Joii t:-

Or - Diameter of the circle touc ring Holt holes.

D, - Pitch circle diameter.
d; . Diameter of bolt hole.

S — Resistance to tearing of
bolLs d — Core dia of bolts
n- No. of Bolts

P, — Circumferetitial Pitch of boits

P, should be between 20ddi to â09d;
d = 0.75t + l0inm d — Nominal diameter of bolts
n = 0.0275D + 1.6 n - No. of bolts
tp' 1.St + 3rnm tt - Thickness of flange
B = 2.3d B - Width of flange
t Do = D 2t + 2B D — Outside diameter of flange
” D¿= 0 + 2t + 2d fip - Pitch circle diameter of. bolts
+J 21Tl1Tl

F = x/4 ((D i)' — (Dy)*] P

F - Force required to separate the flanges
D — Outside Diameter of Pack i'ly
Dz — Internal D iarnetei of Pipe
P - Pressure of the passing fluiJ.

Fb — For ce or load taken uJi by b‹i its

w,t — AI lovable tensi ie stress of la‹› lt near' i‹al
d = 0.75t + l0mm d — Noni inal diameter of bolts '
tt = 1.5( * 3nim tr — Thickness of the flange .

‘ (
i
 ' ftp D + 2t + 4.Gd IJ — Slut .siJc diai Jetcr or rlangc
' Dy D — (3t + 20mm} Op — Pitch circle di‹m›eter

1.3 Square Flanged Pipe Joint:

t = R[ ‹o•+ › ‹o• P›J

According to 1.anies equation
*‘ F = f/4 (Dt )2 I’ F— Force required to separate the flanges
F, = F / ii F; - Force on each bolt

1.. =Outside diameter of the pipe + 2 I3iaineter rif holt

= D + 2t + 2
L - M iiiimiiin 1.engtli of diagonal f‹u the .square
L, =Lf72
Li — Side nrihe ‹c are flanye hctwcct› c•nler ctpcenter ct
bolt ilnles
1.i = Lt + 2d
Lt — Side of the flnnge £nr nil(.s A hnlLs with‹›cit
overhang
d,„= D + d„ — Nominal c›r Ma|s›r diai»eIci cf' l)treatl.s
2t
 z. uzsıc« or rısı”ON .1SSE84IJL1'
2.1 Ucsig›ı ofC)li1ıdcr:

p — A p{ıarent 1 tuqtit udiıı:il .eh csx iii he cyl in‹l‹'ı

let, -- t7tıtsiclc diaıut•lc.ı ol’1 lı‹• c.yliııclc' in nun
i) - ltısitlc dian ctcı’ ‹il’ Hic cyliııder t turu
p - ila.x irıunrı ı’csstırc imeııgine in 4/nun“.

'9 in mm 75 I l)l) I 5P 2tl(1 250 3Ot) . 3 Il 4(l(1 4.50 5()(1

t iti ırım 1.5 2.4 4.0 6.3 8.0 9.5 11 12.5 12.5 12.5

t› — “Fhickı1es.s ‹›f“eh"}’
lincı”

t,.,t.= 0.032D + I.6nzı» or t/3 lor higger c}’linder. 3t/4 f‹›r sı1lallor cylindeı .

Water space fret veer the n\it°r cylinder wall an‹l inn c«
jacket wall l0min for 7fin›nJ cylinder t‹› 7SinM› for
750mm cylinder or â.08JA -I: 6.fin1in.

1.zngtlı of the stroke (1) is geneıatly 1.2.51 to 211

1.eııgth of the Cylinder is I .5"« greaıcr tlıaıı the lengl lı t›f

I ile
stroke i.e. 1. 1 dl

'
 lx —Cyliltder head”thic1ncs.s
D — Cylinder hnre in nem
p —Max. pre s‹iie in.side linc cylinder in N/min*
oe — Allo\vable circuinFerential stiess in IVff’,
e — a constant of valtic 0.1

.Dy — The pitch circle diameter

2.2 Desiqn of piston

Fistun head or crown:

§/ —.ThicLncss of pirtnn l›end (I3ased nu slraiii}

p — Max. gns pre;siire or explosion pressure in
N/mm2
D — Cylinder Bore c›r outside diameter of the
piston in mm.
‹r, — Permissible bending (tensile) stress of piston
material in MP,
For Grey Cl = 35 to 40 MU;
ror N:ckei ci & Arum:n« aiioy = 5s to s0 Mr„ For
forged steel 60to 100 M I•„
t = lul/ 12.56K ( Tt — T E)
m
tjt — 1‘hickness nl yist‹›n licltl (llesed en hcat
transfer)

LI —Fleat flowing through the piston head in

›vntts
or kJ / s

For A iui”ninum y'llcys

I 74.7ñ W/m/°C
T c — Temperature at the cen ter cf piston in "C
Tg — Temperature at tile cclgcs ‹›F tlle pist‹›nIlcaJ °C

The teinperature dif7erence ( Te — “Ft.) mat be laken as ?*2(! "C t, or CI 7ï

°C lor alui iinum.

Heat ft‹›wïrig tl›ro‹igh the pisroi' heacl

(I I)
l‹ = C 1i c t ' . m op (in i‹u )
C — Costant re{›rcsenting II d portiun ‹›f“ Ihe I wat supr
'• to the eiigiiie. ’l’lic v:i fue can he takei as 0.05
f lC V = 11
. ighei’ caiorific va1 ric ‹› i‘ fiie J iii k.1 / k !

—
 45 X IO kJ / K'g for die.«cl
47 X 10 ill / Kg for peti‘‹›l
m — m.ss n f the ftiel u.sell
in g . bi‘ake power’ '‘fiec.
D.p — f4ral:e power of the
engine per cylinder .

t. Thu larger of I 'c values ol ‹H ir taken into a«cntint

2. When fly iS F\uzn1 cr less no ! ibs need to be prcx’icIcd. When th is gi bawl that\ CM m.
rihs rl›u\iId hc provided dci a thickness oI”t/j/ñ tc tip/2.
3. Foi engines IJaviNg length ‹›'"stroke to cylinder bnie (I./lN) ratio Li' •to I .1 a cup i.s
picvided in the top of the p ton having a radius equal t‹› 0.7I3

2.3 Dn•ign ofjiiston rings:

t\ — Radial thickness of tile riny

Pa — Piessure n£gas nn the cyli-zdcr wall in h/min*
Valtie limited from 0.025N/mm 2 to 0.0d2 N/mm'
o, - Allowable bending ( tcnsilo) stress iii Mpa
nValue
R —No.may be 85 Mpa to 1l0M a ror Cl rings
of rings
G =tto bi — Width uf the top land
1.2+p th — ’l”lie maximum ax inl tliicki›rs.s
— Wiclth of the other lends

b2' 0.75tz to tt
()ap Be:ween the free ends of the ring - 3.5 I to 4 t
Gap whom the rings in the cylinder = 0.002D to 0.t)04lJ

4. Piston Barrel:

tj — Thicki es.s nF l3*i ie1

b — radial depth ‹›£ piston ring grt›‹›vc u’IiicI› is
taken as 0.4mm larger lisan the radial thickness
of piston ring (t )
6 t/ + 0.4
tj = 0.0?D + th+ 4.9 mm

5. Piston Skirt:

P - k4aK. Get.S. load ‹›ii the piston

It —
— I/10 of Max. Gas load

I = 0.65 D to 0.8D I — Lengfl nf the {Piston .skit f

 3. DESIGN OF SHAFT COU PLINGS

3. 1 JAuff Coupling:
I) = 2d I 3mtn D - Outside dia ol’slceve.
1. = 3.5d L — Length of the sleeve
’F = n/l 6 . i, [G 4 d — Dia of the 5hali
— d / D] T — 2’ORQUE
1- 3.5d /2 = L/2 transmitted by coupling
4’ = l.w. . d/2 z, — I4M pa f «
(shear failure ofi
I — Length of the kev iii etch xhall
key)
w — Width of the key
T ' •I /2 . c•d/2*| t — Thickness of the key
(Crushing failure of key) z - Shear stress in Key
3.2 Flange Cou pling: n< — Crushing sire.ss in key
D = 2d, I- = 1.5d dj — Nominal Diameter of hcl!.s
d — Sraft dia
D = .3d, Di= 4d D — Outside dia
tr = d/2 D — Dia of bol{ circle
n = 3 for d upto 40rnm n — number of bolts
= 4 for d upto l00irim t/ — Thickness of
* 6 for d upto 1 80mm flnttge
t = d/4. t —Thickness of
protecting flange
‹„‹#.zt — Allowable shear stress for
shaft, bolt and key the material
respectively.
«— Allowable shear strens for fiange
material.
Key: ay ay—Allowable crushing
T = l.w. ir. d/2 stress for
T = 1.(t/2). ri, . (d/2) bolt and key material respectively.
Flange: T-1'orque transmitlcd by the co tip liM s
_ T' n. [D2/2]. z,. tr
“' Uults:
*"' • l+ 4].d ' -!b- I*› i/2j
1 = n.‹I,. ‹,. b. (o /-‹

3.4 Flexible Coupling: |Bushed pin typeJ '

N P,J . dz
I
.
—
I
l
u
b
l.
=
n
gt
lz
I

=
I.
e
n
gt
l›
n
 li — N\unher ‹›l’kiwi
’1’ )W.Tk. [d 2] IN i — lJia ‹›f’pilcli c:it‘clc ‹›(‘
’1’ = I.(t/2) . ct. (d/2) piM Pa <0.ñ to I).Rv/ntm'
I.. = 1.5d W = In:‹d ‹m each piu
4‘ = [n/2JD'‹,tr M — hei diiig mnin an' ‹›tt pil
¢ri = Bencling .stress in pin
z - Shear stress in pin
”y. — Mn ltIlii.s ‹›F secfi‹›fi
r›t”pitts| -‹/32 |c-l i .
d — shaft dia
W — \\*idth nf”kcy
I — Thickness ‹›f” key‘
tt— d/2 ty = d/4
z — Shear stre.ss in lJange
D — Dia of huh
D—
— 2d
@ — PCD
oFpins Dz — (4
3.5 8'tarine Coupling: tn G) d
T- torque
Flange thickness = d’ /3 . transmitted fry tile
Taken of bolt — 1 is20 ii1 1 is 40 cniiglillg
PCD of bolts Dt = 1.6d
Out slde dia of flan e D2 2.2d
Shaft dia 35 to55mm . 56 to I 50mm 15 1 to250irim 2 t 390mnj
Above3@0rniii
No. of Bolts 4: . ‹i 8 10 12

d = shaft diameter
t = (N4] di°‹s n [G}/2
—— shear stress in bolts
Fig 1.1 CIRCULAR FLANGED PIPE JOINT
 Packing

^
B

Souare flanged pìpe joint.

.
 Piston head
OF CFOWfl

Top land
(b )
Ribs Grooves for
Ring compression rings

Groove for
oil control ring
Pston
boss

Piston barrel

. Fig z 1Piston for I.C. engines

.
 Flange

Hub

Kcy Shaft

I.
5d

Key
D = 3d

Fi9 3.2 L n protected type flu! i gc coupling.

Pt rc cw .1anpe ci otÏ
ccti y upgl.
cheese he.id bol' Brass hiish (2 tTlin thick)
-lange

Robber bush.
(6 mm thic fttib

D——
2d

.5 d

FÏ@ 3 .4 Bushe.1-gin flexib)e ‹ cupline.

r-”i9ü. 5 coupling.
Marintyepfle v,ge
 “ ANNA. .UNIVERSITY : : CHENNAI - 600 025
ADDITIOPL *ATA SHAG* IS AP.. RO”ND FOR UNIVERSITY EXAMINATION
with effect from November 2005 s
(
est tio o a n a bo e
:
IS Designat.on
Gld Designation N••+ designation
C 10 10 C 4
C 30 30 C 8
C 40 40 C 8
C 3S /vtn 7S 3S C 8

Suggested Factors of safetv:

Steel / Ductile material
Type of load Cf
Based on Based on Oy
u
Static load 3-4 1.5 - 2 5-6
Repeated, mild shock 6 3 7-8
Reversed Mild shock 8 4 10 - 12
—Heavy—shock J0-15 J-7 15-20

Variable loading :
Endurance limit of the machine member: ( With Factors considered)
(o-!)
( -i A.B.C) / Kf
' A = load factor
V/here,
= 1 for reversed bending
= 0.7 for reversed axial load
= 0.6 for reversed torsion
B = Size Factor
If D < l0mm then
B= 1
If 10 mm < D < 50mm then o
= 0.9 If 50 mm < D < i 00nim then B
— 0.8
If ! 00 mm < D < l50mm
then B — 0.7
C — surface finish factor
 = 0.9 for ground or cold rolled surface

= 0.7 for m.achined su.face

= 0.6 for cold rolled surface
Relation between Endurance limit and ultimate strength:
Steel .i' 0•5
u
Cast Steel p_ = 0.4 p,
Cast Iron n.i = 0.35
u
Non Ferrous metals and alloys o.i - 0.3

Basquin Equation A — at . L'.

nt = 0.9 o, for L = 10° cy‘cles
a. i {endurance limit)— 0.5 n,. for L — 10 cycles
A,B= constants
Endurance strength for loading with different values and parts: ”“

' fn K{ g @u t ‘( u m)

Where, o„ wq = variable and mean stresses for any ‘part’ of the loading cycle
n - 1,2 ,3 ... ... n

Miner’s en aation l or
(N, /’Lj) + (Nz / L2) + •••'
( 1 ' L}) + ( z ' L2) + ... • •• '
1/

Le
N= Number of actual cycles
L= life at that particular part of the load
Reliability factors:
Reliability % Kr
50
90 0.897
95 0.868
99 0.814
99.9 0.753
99.99 0.702

2
 STRESSES DU£ TO INTERFERENCE FITS may be calculated by considering the fitted parts as thick-walled
cylinders, ai ahown in Fig. 3-2, by the following equations:

p‹ -‘ pressure at the contact surface, N/m'

6 - the total Interference, m
d -- Inside diameter of the inner member, m
dz -- diameter of the contact surface, m
dp outside diameter of outer member, m
= Poisson's ratio for outer member
pt - Polsson*s ratio for inner riiember
Ep -- modulus of elasticity of outer
mimber, Ifm
E -‘ modulun of elasticity of inner
member, N/m2
If the outer and inner members are of the
same matedal, the above equation reduces to

After Rs M been determined, then the actual tangential stresses at the various surfaces, in accotdance with
Lamb’s equation, for use in conjunction with the maximum shear theory of failure, may be determined by:

On the surface at d p ,

On the surface at df ,

Stress concentration Factors in welds:

Reinforced Butt Weld 1.2
Toe of transverse fillet weld 1.5
End of parallel fillet weld 2.7
T — Butt joint with sharp comer 2
 — 0 6 for copper — asbestos .
gasket "
= 0.1 for lead gasket

Knuckle Joint: = 0 when no gasket is used.

Proportions:
Diameter of the rod = d
Diameter of the pin, d d

Outer Diameter of the eye, d2 - 2d Dia of

the pin head, d3 - 1.5d Thickness of the

eye, t — 1.25d Thickness of the

fork, t, = 0.75d Thickness of the
pin head, t2 = 0.5d
4.5d Ad

tagonal
end ‘3

Oou ble eye Ïfi head Single eye or

forked end - rod end
1-2d -\d

Split pin
in
Knuc

XNUC FILE JOIN T

S1e•ve an5 Cotter Joint:

Proportions:
Diameter of the rods to be connected = d
Diameter of the •nlarged end, dl = 1.3 d
Outside Diameter of the sleeve, d2 = 2.5d “
Distance of the slot from the sleeve end, a = 1.3 d '\

Length of the sleeve, L = 8d

Length of the cotter, 1 = 4d
Width of the cotter, b = 1.3 d

4 ,
 Distance of the slot from the rod end, c = l.4d
L•ngih of th.e enlarged end of the outside sleeve, e = 0.5 d
Thickness of the cotter, t = 0.3d

Gi b

For h Pn¢i

spigot
end

G
I

A
clearance
N 1- S to 3
mmD
C
O
O.5 T
T
E
R

R
O
I

N
T

hic6ness
f

COTTERED
JOINT
FOR
RODS
Where, p = permissible bearing pressure, < 7 N/mm 2
Splined Connections:
A = total area of the splines = h.1.N
Torque carryingh capacity
= height of
of Spliced Connections,
the splines = (D - d) T
/ 2= p. A. rq
 1 = length of the hub
n = no. ofsp1ir'.es
- mean radius = (D + d) / 2
Units of viscositv :
AbsGlutü VlSCOSity, ! Pa
— s = 103 cP

Leaf Syrinr:
Nip, h — 2PL’ / (nEht )
Wherc, n — to:al no. of!
eaves b = width of
leaves

Loa‹i on t*.e clip bolts require-d

b 2J. to nclose
. P I' n ( 2 ng + 3 )
th• gap:
where, rt, = no. of extra trill iength leaves
n = no. of$raduated !eaves

-—- ’APPROVED DATA SHEETS

. FROM PAGES 01 — 06

CONTROLLER OF EXAMINATIONS DIFtECTOR,

ACADEIvHC CGURSES