••

, BALL AND ROLLER BEARINGS

Designation Application Type and Figure

.
Deep groove ball bearing

Self aligning ball bearing

Can carry considerable thrust load apart
From radial load - high speed

Minor angular displacements of shafts

9
will not affect
~

Single row angular contact ball

bearing * For heavy axial loads
g
Double row angular
ball bearing
contact Can carry radial loads with heavy thrust
in both directions

High carrying capacity, self aligning -

00
Spherical roller bearing
for heavy radial loads with .considerable
axial load in both directions .e§
Cylindrical roller bearing' For heavy radial loads at high speeds-
permit slight axial displacement §
Taper roller bearing
* For combined radial and axial loads
@
Single thrust ball bearing For axial load in one direction only
R~ I(~
Double thrust ball bearing For axial loads acting on both directions

~ ~

Spherical roller thrust bearing For heavy axial loads - high speed - self
aligning
~ 1S2
• Note: Always adjusted towards another bearing capable of carrying axial load in the opposite direction

tnEslGN DATA - PSG TECH 4.1

 /'

BALL AND ROLLER BEARINGS

Equation omenclature

F r radial load, kgf

Equivalent load
F • axial load, kgf

P = (XF r + YF .) S C basic dynamic capacity, kgf

C 0 basic static capacity, kgf
P equivalent load, kgf
Dynamic Capacity
S service factor
X radial factor
Y thrust factor
F m cubic mean load (axial or radial)
n revolutions
t time
K = 3 for ball bearings
mr million revolutions
K = 10 13 for roller bearings
L required life of the bearing in million revolutions
L 10 Life of the bearing for 90 % survival at 1 mr
C 1 P may also be obtained direct
from the charts on pages 185 and 186 p probability of survival
p 10 probability of survival for 90 % or 0.9

Probability of survival L 50 median life based on 50 % survival

lIb L' 10 calculated life of selected bearing for the given load
L [In(lIP)J for 90 % survival &
In (l/P'lo) = In (1/0.9) = 0.1053
~ = In (lip 10)
b = 1.17 for a median life. = 5 L 10

b = 1.34 for a median life = 4.08 L 10

Cuble mean load: (F a or F r) (for deep groove ball bearings)

+""r'
For a system having x bearing each having the probability as p,

Fm ~ [ ~in '+2: n, the survival probability, p system = Px

(revolutions varying) Service factors for bearings carrying geared shafts

OR S
Rotary M/c with no impact l.l - 1.5
Fm ~ [ Fi t ,+ :,: t, + """J '" Reciprocating M/c J.3 - 1.9

(time varying) M/c with pronounced impact, hammer mills etc. 1.6 - 4.0

DECREASE IN CARRYING CAPACITY AT HIGH TEMPERATURES

8 aring temperature °C - 125 150 175 200 225 250

Deerea e in capacity - 5% 10% 15% 25 % 35% 40%

4.2 DESIGN DATA - PSG TECH

 EEDLE BEARINGS

Lh = 16~66 (;) p p = 130 for line contact

(The life expectancy in hours, L h can be obtained from L nominal Iife in 10 5 metres
thenomogram given for Roller Bearings, p. 4.7)
C dynamic load capacity, kgf
ROLLING BEARINGS FOR LINEAR
MOVEMENT p equivalent bearing load, kgf

. 5
L In 10 metres
H single stroke length, m

833 L
Lh = Hn
in hours n frequency of oscillation in strokes / min

T
p 1 T duration in seconds with periodically
T f
0
F P (t) dt
varying load or total time of operation
with non- periodically varying load
:::: 0.76 F max

p = 130 for needle bearings

For variablespeed and load use equations given on
p.4.2

10 F rnax maximum load in the periodic load

With the index p instead of 3
3

RECOMMENDED LIFE VALUES

Life, L h in
Type of operation
operating hours
Infrequently operated 500

Brief operation only 4000 to 8000

Intermittent operation 8000 to 15000

f
. One shift operation 15000 to 30000

Continuous operation 30000 to 60000

Continuous operation with high

100000
production capacity

DATA· PSG TECH 4.3

 /

, EQUIVALENT BEARING LOAD

F F I>
Type of Series
_I se __ e
Fr Fr e
Bearing (SKF)
X y X y

Series EL, R ~ = 0.025 2 0.22

~eIl Co .
= 0,04 1.8
~'5
eIl~
160,60,62,63
64,EE,RLS = 0.07 1.6
0.24
0.27
=-~
t:;
Q= RMS
= 0.13
= 0.25
1 0 0.56 1.4
1.2
0.31
0.37
= 0.5 1 0.44

ell 72B, 73 B 1 0 0.35 0.57 1.14

1::1
••••• 'C
..!!~•• 72BG,73BGe 1 0 0.35 0.57 1.14
g,1::I~
~8:; 72BG, 73 BG t 1 0.55 0.57 0.93 1.14

.= 32,33 1 0.73 0.62 1.17 0.86

2200 - 2204 1.3 2 0.5

ell
1::1 2205 - 2207 1.7 2.6 0.37
'C
J
•• 2208 - 2209 1 2 0.65 3.1 0.31
= 2210 - 2213 2.3 3.5 0.28
~•• 2.4
2214 - 2220 3.8 0.26
1::1 .
'! 2221 - 2222 2.3 3,5 0.28
=
:=••~
2301 1 1.6 0.63
rI.l 2302 - 2304 1 1.2 1.9 0.52

2305 - 2310 1.5 0.65 2.3 0.43

2311 - 2318 1.6 2.5 0.39

22205C - 22207C 2.1 3.1 0.32

"iii
~
••• eIl
~ 1::1 22208C - 22209C
- 2.5 3.7 0.27
'C='C
~ 0 ••
.I::I~~
~ = 22210C - 22220C
22222C - 22244C
1 2.9
2.6
0.67
•
4.4

3.9
0.23
0.26

::!••• 32206 - 32208 1.6 0.37

~-@ 0.4 1.45 0.41
••• •• 32209 -32222 1 0
1~ 32224 -32230 1.35 0.44
~

e A pair of bearings mounted in tandem

t A pair of bearings mounted back to back or face to face.

4.4 D'ESIGN DATA - PSG TECH

 LIFE OF BEARINGS·

Bearing Life
Class of Machines
Working Hours

Instruments an~ apparatus that are used only rarely

500
e.g. Demonstration apparatus, sliding door mechanism

Machines used for short periods or intermittently and whose .break - down 4000
wouldnot have serious consequences. to
8000
e.g. Hand tools, lifting tackle, agricultural machines, domestic appliances.

Machines working intermittently and whose break - down would have serious
consequences. 8000
to
e.g.
.
Auxiliary machines in power stations, conveyor plants, lifts, m / c tools
used infrequently.
. 12000

12000
[Link] use 8 hrs / day and not always fully used
to
e.g. Stationary electric motors, general purpose gear units. 20000

Machinesfor use 8 hrs / day and fully utilized 20000

e.g. Machines for engineering industry - cranes of bulk goods, ventilating to

.
fans, counter shaft in gear box. 30000

. -.
Machinesfor continuous use 24 hrs / day.
40000
e.g. Separators, compressors, PumPSI mine hoists, stationary electric to ..
machines, on-board naval vessel machines. 60000

Machinesrequired to work with a high degree of reliability for 24hrs / day . 100000
.',,; .. to
e.g, Pulp and Paper making machinery, public power plants, mine pumps, 'r
0

",.
'.-"t, •

waterworks, on-board merchant ship machines. 200000

.'

lISlGN DATA- PSG TECH 4.5

 /

MATERIALS AND APPLICATIONS - JOURNAL BEARING

Materials Characteristics Limitations Applications

Wood Self lubricating, low Light loads at high Conveyors

(maple lignum vital) cost, long life speeds, under 65°C

2
Cast Iron Low friction, low cost Not over 35 kgf / em Cam shafts, light
and 40 rnImin transmission

Steel Low cost Light loads 45 m / min Guides

2
Bronze bushing Low cost, simple Loads upto 210 kgf / em , All equipment
construction speeds upto 270 rnImin

Heavy babbit liner on Long life, low Steady loads under Motor, turbine,
2
steel or cast Iron friction, must have 70 kgfl em shafting
good lubrication

2
Light liner on steel or Heavy duty, general About 350 kgf / em Gas and diesel engines,
bronze backing pupose, good for and 1200 rnImin compressors
dynamic loads

2
Rubber Low friction, resists About 5.5 kgf / cm , Marine propellers.
abrasion, shock needs water Pumps, Turbines
absorbent, long life lubrication

Carbon graphite No lubrication Under 455°C, Electric motors,

2
needed, light duty 40 kgf / em ,at low meters, conveyors
applications speeds

Moulded plastic Low friction, Stronger About 120 m / min and

2
laminate than babbitt when J 75 kgf / em ,must be Pumps, propellers.
water lubricated well cooled

Moulded plastic Low friction, clean Low loads if used at Dairy, textile and food
high speeds machinery

Sintered bearings, Self lubricating Low loads,· All inaccessible places,

Steel, bronze high speeds typewriter, electric
fans, instruments,
piston rings

7.30 DESIGN DATA - PSG TECH

 DESIGN PRACTICES - JOURNAL BEARING

BEARING
PRESSURES LUBRICANT
MACHINERY .BEARING LID ALLOWABLE

kgfl em
2
?J .z nIP mln
Stationary High Main 1.5 - 3.0 17.50 15 355.6
speed steam Engines Crank pin 0.9 - 1.5 42.00 30 85.3
Wrist pin J.3 - 1.7 126.00 25 71.1
Gas and Oil Engines Main 0.6 - 2.0 49 - 84 284.5
(Four Stroke) Crank pin 0.6 - 1.5 108 - 126 20 - 65 142.2
Wrist pin 1.5 - 2.0 125 - 154 71.1
Gas and Oil Engines Main 0.6 - 2.0 35 - 125 355.6
(TwoStroke) Crank pin 0.6 - 1.5 70 - 105 20 - 65 170.7
Wrist pin 1.5 - 2.2 84 - 125 142.2
Aircraft & Main 0.8 - 1.8 56 - 119 213.3
Automobile Engine Crank pin 0.7 - 1.4 105 - 245 8 142.2
Wrist pin 1.5 - 2.2 161 - 350 113.8
Reciprocating Main 1.0 - 2.2 17.5 426.7
Compressors and Crank pin 0.9 - 1.7 42 30 - 80 284.5
Pumps Wrist pin 1.5 - 2.0 70 142.2
Centrifugal Pump,
Motors and Rotor 1.0 - 2.0 7 - 14 25 2844.5
Generators
Machine Tools Main 1.0 - 4.0 21 40 14.2
Steam Turbines Main 1.0 - 2.0 7 - 20 2-16 1422.3
Railway Cars Axle 1.9 35 100 711.2
Marine Steam Main 0.7 - 1.5 35 30 284.5
Engines Crank pin 0.7-1.2 42 40 213.3
Wrist pin 1.2 - 1.7 105 30 142.2
Transmissions [Link] 2.0 - 3.0 1.8 25 1422.3
Gyroscopes Rotor - 60 30 782.3
Shafting Self Aligning 2.5 - 4.0 II 60 426.7
Heavy 2.0 - 3.0 II 60 426.7
Cotton Mills Spindle - 0.07 2 142231
Punching and Main 1.0 - 2.0 280 100 -
Shearing Machines Crank Pin 1.0 - 2.0 560 100 -
RollingMills Main 1.0 - 1.5 210 50 142.2

2
~, absolute viscosity, centipoises n, speed, rpm P, pressure, kgf / em

DESIGN DATA - PSG TECH 7.31

 TYPICAL DIAMETRAL CLEARANCES, IN MICRONS

Upto shaft diameter, mm 12 25 50 90 140

Automotive Crank Shaft
Babbitt lined bearing - - 38 63 -
Cadmium Silver Copper - - 50 75 -
Copper Lead - - 63 88 -
Precision spindle, hardened,
ground, lapped into bronze
bushing;
v m < 160 m/min 7 to 19 19 to 38 38 to 63 63 to 88 88 to 125
2
P < 35 kgf/cm ;
0.2 to 0.4 microns rms

Precision spindle, hardened,

ground, lapped into bronze
bushing; I

V m > 160 m/min

13 to 25 25 to 50 50 to 75 75 to 113 113 to 163
2
P >·35 kgf/cm ;
0.2 to 0.4 microns rms

Electric motor or generator;

.
ground journal in broached 13 to 38 25 to 50 38 to 88 50 to 100 75 to 150
bronze or babbitt bushing ;
0.4 to 0.8 microns rms

General machine practice,

turned or cold-rolled journal
50 to 100 63 to 113 75 to 125 100 to 175 125 to 200
in reamed bronze or babbitt
bushing;
0.8 to 1.5microns rms

Rough machine practice,

turned or cold - rolled journal
75 to 150 125 to 225 200 to 300 275 to 400 350 to 500
in poured babbitt bearings;
1.5 to 3.8 microns rms .

- 6
P Unit load kgf I cm 2 I micron = 10 meter
V"I Surface speed of journal

7.32 DESIGN DATA - PSG TECH

 HYDRODYNAMIC JOURNAL BEARINGS

Journal

W
At Rest At start During Running
MECHANISM OF LUBRICATION

GEOMETRIC RELATION FOR ANY

JOURNAL BEARING
(Shown here partial clearance bearing)

GEOMETRIC RELATIONS FOR A CLEARANCE BEARI G

Clearance ratio, CID D journal diameter, em
C diametral clearance, em
Eccentricity. e =~ 2 - h
0
h0 minimum film thickness. em
E attitude, dimension less
Eccentricity factor or cp attitude, angle
L Length of bearing, em
Attitutde, E = 2e = 1- 2ho W Load, kgf
C C P bearing pressure on projected area,
2
Film thickne at any kgfl em
C
angle e , h =""2 (E cos e + I) e eccentricity, cm
n speed of journal, rpm
C n' speed of journal, rps
Minimum film thickness, h 0 =""2 (~- E )
Z absolute viscosity of the oil, centipoise

DESIGN DATA - PSG TECH 7.33

 HYDRODYNAMIC JOURNAL BEARINGS (contd •..)

Sommer fe1d number, S __ (Zp' n') i\ DC )2 u Kinematic viscosity centistokes

Z absolute viscosity,
s = (2 + 6 2) ~ I_ 6 2/ 12 1t2 6 for LID = a
kgf see I cm
2
=
Z
7
9.81 x 10
Coefficient of friction
P hydro dynamic pressure developed
r------------------------------------------4 at any angles a, kgf I cm
2
McKEES EQUATION
2

~ = 3:~;; ( Zpn) ( g ) + k inlet pressure, kgf I cm

2
for lightly P max maximum pressure. kgf I em
PETROFF'S EQUATION ~ loaded bearings 3
S > 0.15 P density of the oil, kgf I em
~ =21t (Z';') 2
(g) Po Pressure at a = 0°

0~010
~+\_f_--I---+-_+-__4-__I

k ,
0.005

t-- -
o 0.5 1;0 1.5 2.0 2.5 3.0
L
If
2
= C (1+26 ) for medium or heavily S Sommer feld number,
D 36 loaded bearings dimensionless
S < 0.15
~ coefficient of friction
Reynolds' equation for pressure distribution at any angle a q oil flow through the bearing.
3

p _p 0 = 20 Z' uD 6 ( 2 : 6 cos a ) sin a2] em Isec .

C
2 [ (2 + 6 ) (l + 6 cos a ) axial flow of oil. cm I see
3

Load capacity
q si axial flow of oil due to inlet

W = 20 Z I U L ( ~ f [(2 + / ~ ~ 1 _ 62 ]
C'
pressure em I see
3

specific heat of oil 17100 kgf

Heat generated. H g = ~W'v kgfm lmin cm I kgf °C
2
(a t + 18) L0 6t 0 temperature increase of the
Heat dissipated, H d = kgfmI min
K oil °C

7.34 DESIGN DATA - PSG TEC]

 HYDRODYNAMIC JOURNAL BEARINGS (eontd •..)

DIMENSIONLESS PERFORMANCE PARAMETERS

D
Coefficient of friction Variable, J.1 C
Flow variable, 4 q/ DC n' L
Flow ratio, qJq At increase in bearing sur-
face temperature from
Pressure ratio, P/Pmax ambient temperature, °C
pC' Ato
Temperature rise variable, k constant for Mckees
P
equation
FLOW THROUGH THE BEARING
u surface speed of Journal
Axial flow in a 3600 bearing, pressure fed, through a cylindrical
hole at the centre m/min
3
2
qsi = ~ ~j, (tan·l1t~ ) (I + 1.5 e )
K constant for heat dissi-
pation, 437 for heavy
Flow is 2 to 3 times greater when the feed hole is located construction, well venti-
in a longitudinal groove lated. 775 for light
With the feed hole in a central circumferential groove construction in still air
3 •
1t 0 C Pi
=-------'- (
1 + 1.5 e 2) h •v average film thickness, em
24 Z' L
Energy increase of the oil = q pC' A t 0

h film thickness at any

AVERAGE TEMPERATURE RISE angle.B, em

Oil ring bearings (still air) , At. = 2At F frictional force on the cap,
kgf
Oil bath bearings (still air ) , At a = 1.3 At
Ur frictional loss in the cap,
Waste packed bearings (still air ) , Ata = 2.5 A t
kgf m/min

Design oil film temperature, 60 - 95°C

2
A sliding area of the cap, cm
FRICTIONAL LOSS IN THE CAP

Average film thickness in the cap At. difference in temperature

of oil and ambient
hav = C (I + 0.74 e 2) temperature, °C
2
Z'Av
F =
0.6 h a v
Ur = F u

DESIGN DATA - PSG TECH 7.35

- HYDROSTATIC BEARINGS

PLANE PAD
W load on bearing
RECTANGULAR & CIRCULAR Supply pressure
Pf

A total bearing pad area

"e'" --
..:l
W = Pc AA p. -
A factor for effective area

Refer fig. 1 for rectangular pad

3 --
~ Q = p h , PB_ Refer fig. 2 for circular pad
~ j

~ 11 -
P dimensionless bearing thrust, fig.3

Q volume rate of flow of oil

CII'" -
'c=~e
~= A = Pf A A
-
i
B factor for flow
~~ ho
= '" Refer fig. 1 for rectangular pad

Refer fig. 2 for circular pad

11 absolute viscosity of oil used

-.ce
=
CII
a..'" R.£
ho design film thickness
.~f ~ =
~ :::I Pf
Q'" h bearing stiffiness
'"a..
~
-
Q.
A dimensionless stiff mess parameter

Refer-fig. 4 for capillary and

orifice bearings
. 11 v
2
= [ ~A~]Y2 Po recess pressure
= Pc h 0
-.ce
...• ~ design pressure ratio
"e=
y
choose 11 and h 0 to satisty the above relationship
= 0.5 (recommended)
[Link]I
Recess depth = 20 h 0 v linear velocity of bearing
a~
Q.
Ac effective friction area
0 Temperature rise of the lubricant,
= A - 0.75 (recess area)
~T = 2 Pc
Jp c, ~T temperature rise of oil

J mechanical equivalent of heat

•...e Use figure 5.
.cq,j" p mass density of oil
C111Ii ~
:::laoS Assume a mean pressure in the pad as
~'a Cv specific heat of oil
~'" -+ (supply pressure)

7.42 DESIGN DATA - PSG TECl

 SPRINGS
P axial load, kgf
Helical Springs
D mean diameter of spring, em
Circular Section Rectangular Section
d diameter of wire, cm
=oK 8PD K ~PC Q2PO
't = s 2 t = C spring index, 0 / d
s 1t d 3 2
1td 2 t b
3
8 PC 3n Q(1t P 03n b breadth of wire, cm
8PD n
y= 4 = y = 3
Gd t thickness of wire, em
Gd 4 G t b
4
Gd Gd 4 G t 3 b n number of active coils
q = = q = 3
8 D 3n 8 C 3n Q,1t o n
1.6 , r shear stress, kgf / em
2

,
I

VI
G modulus of rigidity, kgf / em
1.5
~
\ y deflection of spring, em
ri
0 1.4
\ q spring rate or stiffness, kgf /
~
o \
~ K. Wahl stress factor
rn 1.3
\
rn
w
0::
~
rn
.....t
:J:
1.2 >-
- zc
~
rn
e
Z
-, ...•.•.
QI,Q2 factors for springs of
rectangular section

~
<
-:;:;: - W
0::
Q.
rn
"-...., - ........ ~~
U resilience, kgf em

1.1 z
i - ~
~ :J:
U
. f lowest natural frequency for
circular coil helical springs,
~
0:: ::l NORMAL~NGE
~ ~ 0
.....t cycles per second
1.0 ~ U
I Y specific weight of-spring
2 4 6 8 10 12 14 16
3
SPRING INDEX, C material, kgf / cm

U = Py g gravitational constant,
2 b 2
981 em / s
Wahl stress factor

{~~G
Lf free length of spring, em
4 C-1 0.615
Ks= + Ls solid length, ern
4 C-4 C

(may be obtained from the graph also) p pitch of coils, em

a helix angle, < 12°

Factors for rectangular wire section
solid deflection, em
b/t 1 1.5 2 3 4 6 8 10 (l
"-
5.10 3.36
~ clearance between concentric
Q1 7.09 4.36 3.80 3.56 3.26 3.21 3
springs
Q2 4.79 4.35 4.05 3.71 3.52 3.35 3.25 3.2 3

7.100 DESIGN DATA - PSG Tl

 ~l'RINGS (contd •.•)

lowest natural frequency m mass of the active coil in

the spring
f = (q/m)Y2 d -rag
'\I sy=- , f I frequency of the applied
2 2
7t D n load
Check for surging
't s shear stress in spring when
f ~ 12 f I compressed solid

Check for solid stress

't s < 0.5 o u for hard drawn carbon steels

< 0.5 cr u for alloy steels

To avoid Buckling

L r < 3
D

for If-
L
> 3 the spring must be suitably guided

Coaxial springs

(suffixes 1, 2 refer to outer and inner springs respectively)

1', 1'2<{1'
Plain Plain and
Ends Ground Ends

( C~2 )

The winding of the springs should be of opposite hands

End conditions and length of springs

Type of end Total Free Solid

coils length, Lf length, L s
n pn + d dn + d

n pn dn
n+2 pn + 3 d dn + 3d Squared Squared and
Ends Ground Ends
Squaredand Ground n+2 Pn + 2d dn + 2d

7.101
 . SPRINGS UNDER VARYING LOADS

Repeated Loading

=
't 3
~.
8kSh PmC
..
II

'tm = 7t d2

2'tu "t y/n

+ ---
n 'te
VARIABLE STRESSES IN SPRINGS
Curvature factor, k c
Pa amplitude load, kgf
C 3 4 6 7 8 9 10
kc 1.35 1.25 1.15 1.13 1.11 1.1 1.09 Pm mean load, kgf

2
'tm mean shear stress, kgf I em
Static Approach to Varying Loads
2
*Recommended 't. amplitude shear stress, kgf I cm
No. of cycles Classification
Design stress [ t ]
'te endurance shear stress for
~ 10
6
Severe Service
~ repeated loading
0.263 C1 u
4 6 Wahl stress factor, k s h k c
~ 10 but < 10 Average Service - 0.324 c u ka
4 •k , h direct shear factor
<10 Light Service - 0.405 c u
kc curvature factor
* For extension springs 0.8 times the values
n factor of safety
recommended for compression springs may be used ..
P total load on the spring, kgf
EXTENSION SPRINGS Pj initial load to separate the coils, k
3
rt't.I d 'tj maximum value of initial stress,
= = 2
8D 8C kgfl ern

--IRffi IT\\~
The calculations
the compression
for extension springs are done as per
springs based on the total load P. ~tw ..-.-.-~
Approximate maximum stresses at initial tension

C 3 4 5 6 7 8 9 10 11 12 13

't;
2
1700 1600 1430 1300 1160 1000 930 830 760 690 500
kgf I em

7.102 DESIGN DATA - PSG TECH

 COIL SPRINGS
SELECTION OF SPRING INDEX
100000
80000
60000 /
V
./'
40000
:<. ./

20000
'f/
~~
",

,.'
<$:~ ,. ,.
,.
,. ,.
o /
~
.. ",
10000 r-W
r-::E
.6000 r-;:) 1/ ,
,
I~ r-
6000 r-O
->
:IE
..J

," /
,/ I'
.;
.;
,

•• 4000 -;:)
o :IE
-z / ~~
f\.D
:i V /'
/
If'
0
200or-
/
,

1000
800
I
I
V / /
/
~DI

,
600
r ~
I~
,, ,.,
.:»:

400 '/1 ./

J
G«,,~/
III
if II
I "
~\¥-\~-J~
I- 200
Z
~
III
Z
o
o
z
100
80
f' f1/ I
,
/
V
C)
ii) 60
I .J
'"
W
o 4o I fA
/
/
20 /
/
o J /
2 4 6 8 10 12 14 16 18 20 22 24 26

SPRING INDEX, C = Did

P axial load, kgf

Q number of inactive coils
y deflection, ern
D 0 outside coil diameter, em
2
t allowable shear stre s, kgf / em D i inside coil diameter, ern
2
G modulus of rigidity, kgf / em

IGN DATA - PSG TECH 7.103

 I

LEAF SPRINGS

Treating the spring as a cantilever beam of

uniform strength
6PL 3
crb = 6P~ y 3
(
nbt En b t
2PL.J --;t:ifi~-SEMI ELLIP
ip, h = --:::"::"":::::'-c:- 2 P LEAF SPRING
3
n E bt --=-I ----...Pu P
Load on the clip bolts
P =------
2 n e n g P
..=====:::;:=='~ ~ CANTILEVE
required to close the gap, b n ( 2 n g + 3 n e) ~ •• I..-B-I SPRING
Spring with extra full length leaves EQUIVALENT BEAM
OF UNIFORM
12 PL STRENGTH
P P
~.
crbe = 2
18 PL 2 P load on the spring, kgf -
bt (3n e+2n g) Y deflection of the spring, em
_______ ~-----------~L Length of the cantilever beam (spring) em
12 P L 3 b width of the leaf, em .
y
3 t thickness of the leaf, cm
bt (3ne+2ng)
number of leaves in the spring
r-------------------------in number of graduated leaves
BELLEVILLE SPRINGS n g

n e number of extra full length leaves

bending stress, kgf / em 2
P 2 EY 2 [( h - ~) (h _ y) t + t 31 o b
(l-v
____________________
)M(d2o) J
~crbe
crbg bending stress in graduated leaves, kgf I em 2
bending stress in extra full length leaves
2
Ey kgf / em
[Cl(h-~)+C2tJ E modulus of elasticity, kgf / em 2

6
M
1t log e( ~ °) P axial load on the spring, kgf
1

d j internal diameter, em
d ° outside diameter, em
Y deflection, em
t thickness of the disc, em
h free height minus thickness, em
2
E modulus of elasticity, kgf / em
v Poisson's ratio
2
c stress at the inside circumference, kgf / cm
M, C C
I , 2 constants

7.104 DESIGN DATA - PSG TECH

 FLYWHEELS

.6.E

2 2
Do +(Do-2h)
8 for rim fly wheel

_ D 2 / 4 when h is small

D 0 2 / 8 for disc flywheel

v xDN
For C I Flywheel

v < 1500 m / min for H. P < 100

< 2000 m / min for H. P > 100

For cast steel flywheel

v 3000 - 4000 m / min

w 1tDbhy
b/h = 0.65 - 2 .6.E Excess energy

For belt pulley flywheel b should be 3 to 5 I Mass moment of inertia of the

em wider than the belt flywheel

Stresses in the rim k s coefficient of fluctuation

2
speed (refer table)
Tensi·1e stress due to centn ifu gal force c 1= --Y v 001-002
2 2 g
· 1t V Dy 00
Ben d109stress, cr b = ---::-2-~
n gh 00 I ,002 and 00 are maximum, minimum
c total = % cr I + )4 rr b
and mean angular velocities
respectively
2
s 350 kgf / em for C. I k radius of gyration of flywheel
2
o t < 65 kgf / em for C. I 00,0 outside and mean diameters of
2 the rim
< 280 kgf / em for cast steel
h thickness of the rim
Stresses in the arm (at the hub End)
v mean rim speed
. M CO-d)
Bending stress o bI = _,-I --- w weight of the rim ofthc flywheel
nZyyD
b wi th of the flywheel
2
For C. I cr b I < 130 kgf / em
2 y Specific weight
< 65 kgf / ern , for severe load
n number of arms 6,8 or 10
Section of arm
M transmitted torque
V
I

a = 64 Z YY with C = a /2
p T I' T 2 belt tensions

7.120 DESIGN DATA - PSG TE

 For belt pulley flywheel

(TI-T2)(D-d)
a b2
2 n Z yy

2
8 bh Y v
n c a g

a total abl + ab2 + 0'(

2
< 200 kgf / em for C I

Values of K s

Driven Machinery Type of drive Ks

Hammers, Crushers, Punch Presses Belt 0.2

Compressors, Concrete mixers, Excavators Belt 0.1 - 0.14

Pumps, Shears Belt or flexible 0.04 - 0.05

coupling

Metal working and wood working machines Belt 0.033

Flour, Paper and Textile mills Belt 0.02 - 0.025

Compressors, Pumps and Similar machines Gears 0.02

Spinning machines, Coarse to fine Belt 0.016 - 0.02

D. C. generators single or parallel Belt 0.03

D. C. generators single or parallel Direct coupled 0.014

A. C. generators single or parallel Belt 0.016

A. C. generators single or parallel Direct coupled 0.01

DESlGN DATA - PSG TECH 7.121

 CONNECTING ROD

AXIAL LOAD ON THE CO NECTING ROD 2

p gas or steam pressure kgf I em

Load due to gas or steam pressure diameter of piston, ern

d
_lI. d2p
FG - 4 R weight of reciprocating parts, kgf

Inertia force due to reciprocating parts co angular velocity, rad I sec

Fj =g-R 2 [
co r cos B + (llr)
cos2e]
I length of connecting rod, em

r radius of the crank, em

Effective force on the piston
F = FG±F 3
y specific weight, kgf I em
Axial load on the connecting rod
F a area of cro s section at mid -
2
Fa ection of connecting rod, em

3
Z xx modulus of section, ern
By John on's Formula

F a ~ [1 _ ~ (Lke)2] n factor of safety, 3 to 6

a n 41t-E
L e equivalent length, em
I ERTIA FORCE
k radius of gyration, ern
Inertia force on the connecting rod
at 1 I 3 l from the crank pin
•• y 2 E modulus of elasticity, kgf I em
2

P = 2 g a I co r (for a. = 90 0 )

p inertia force, kgf

Bending stress due to inertia force
2 2 a. angle between crank and
ya I w r
CJbmllll = _M connecting rod, degrees
.9..,.3 g Z xx

At mid section
2
a = 11 t
I =419t4•
xx 12
2 2
k xx=3.18t

Depth at big end 1.1 to 1.2 times the depth at the mid section

7.122 DESIGN DATA- PSG TECH

 CRANK SHAFTS - Proportions

D2
a 1.5 de

,• - b 1.35 d

1c 1.25 de

D( 1.75 d

I D2 2dc
b

t b 1 to 1.25 d

D1 1.4 d c
tp

OVERHUNG CRANK

w
I' (

I
:::::1 t 1.7 d

[Link]
,'-r ....
,, 1c
I
_~I ___ L._
--- -- '1:1
~--- 1---- - \ I
-1-" ~
, ....
I
W 1.14 d

a:

-.-
I

~-- --- - - 1---- ---~ ~ -'1:1

I. t .I. .1. t .1
CENTRE CRANK

DESIGN DATA - PSG TECH 7.123

 /

RIVETED JOINTS

Length of the rivet

L t + ( 1.5 to 1.7) d

D '" 1.6 d

h ~ 0.7 d
crl <X E ~ t

Strength of rived joints

Shearing of the rivet
2
F
i < n -4-
- nd [
r ] Riv

Tearing of the Plate between rivets

F
i ~(P - d) t [cr t] pI
t-------------------1 d diameter or rivet
Tearing of the Plate edge along the D diameter of rivet head

length [ e - d / 2 ] D I internal diameter of pressure vessel

e margin of plate
~ s 2 ( e - ~) t [ 't ] pI
E Young's Modulus
r-------------------------~ F force acting on the joint
Cru hing of the surface of joint between
F I force per pitch length of the joint
rivet and plate

F
h
.
height of rivet head
number of rivets
t-------------------1 k number of rivets per pitch

For variable load, Design Stresses k t theoretical stress concentration factor for
plate with hole
= (Design stresses under static load) x r
length of shank of undriven rivet

r n number of cross sections under shear

1 _ 0.3 F min p pressure of fluid inside the pressure vessel
F max
P Pitch
r-------------------------~ Thickness of the plate
trong riveted joints ~ t temperature drop

[ For machine units. Columns trus es etc. J [cc) Allowable compressive stress 2100 • 2400
2
kgf I cm for steel
F
2 [o.] PI Allowable ten~ile stress of plate ~ ['t] Riv
nd [ 't ] Riv
[tJ Riv Allowable shear stress of rivet 1000 - 1400
2
> F kgf I ern for steel
-td[crc]
['t] PI Allowable shear stress of plate ~ 0.8 ['t] Rlv

7.124 DESIGN DATA - PSG TECH

 ./

.
RIVETED JOINTS (contd ...)

Tight strong riveted joints

[ For pressure vessels]
i' Tensile stress induced in the hot
4F' driven rivet when It i cooled
2
s [ ~] through ~t
nk.7td
(l Coefficient of linear expansion
DIP P for longitudinal joint
F' = Efficiency of joint allowable
II
2
[~] Coefficient of sliding
DIP P for circumferential joint
4 0 Corrosion allowance for thickness
of plate
DIP
t = + 0
r correction factor for variable load
211[crtlPl

0 = 0.1 to 0.3 em

Characteristics of strong joints made of carbon steels

Diameter Margin of Eftici ncy, 11

Type of joint Pitch, P
of rivet, d Plate, e % for k t = I
Single riveted lap joint 2t 1.5 d 3d 67

Double riveted lap joint 2t 1.5 d 4d • 75

Single riveted, single strap butt joint 2t LSd 3d 67

Double riveted, single strap butt joint 2t LSd 4d 75

Single riveted, double strap butt ~oint 1.5 t 1.5 d 3.5 d 71

Double riveted, double strap butt joint LS t 1.5 d 6d 83

Characteristics of tight strong Joints

DIP
C =-2- Diameter of Pitch p Efficiency 11 [l;]
Type of joint
kgf / cm Rivet d, mm mm % for kt= 1 kgf/ em
2

Single riveted lap joint Upto 500 t+ 8 2d+8 56 - 60 600 - 700

Double riveted lap joint 350 - 950 t+ 8 2.6t+ 15 70 600 - 650

Tripleriveted lap joint 450 - 1350 t + (6 - 8) 3 d+22 75 550 - 600

Double riveted, double

strap butt joint 450 - 1350 t + (5 - 6) 3.5d+15 75 2 (475 - 575)

Tripleriveted, double
strapbutt joint 450 - 2300 t+ 5 6 d+20 85 2 (450 - 550)

ESIGN DATA - PSG TECH 7.125

.
, '::>"
-.;,,~
 BOLTED JOI TS

312 load taken by connected parts, kgf

F c
Fe cr Y S (to be used when F I is not known)
15.3 F e safe external load, kgf

Mt Cd F i Fi initial tension in bolt, kgf

C 0.2, for average un lubricated bolts F t total load on bolt, kgf

0.15, for lubricated bolts 2
S tress area of the bolt, ern

F, C torque coefficient

d nominal diameter of bolt, em

( k b
Fe h grip of the bolt (total thickne s of
Where ~ F h k b + k c )
parts being clamped), cm
k
Fe = F. 1 - ( k b + k,
c
) Fe> 0
k
k c
b > spring con tant of bolt and
connected part

L b Length of the bolt

For the joint to remain closed
L c thickness of connected parts, cm
SE b
k c A c equivalent area of the connected
L b
2
parts, em

d e equivalent diameter of the plate in

. compression

de (nut or head width aero s flats) + ~ E Young's modulus

cr y Yield stress of bolt material,

1 l 1
k; -k
I
+ -k
2
+ where kgf / em
2

2
endurance stress, kgf / ern
etc. are the spring constants of the individual
connected parts M applied torque, kgf / em
Ac EI AcE2
; k2 = etc. N factor of safety
LI L2
k f fatigue stress concentration factor
I----------------------l for the threads.

For varying loads 4.4 to 5 for medium carbon steels

5.6 to 6.4 for heat treated alloy

1 aa steels
N a _I
cr m e c a mean and amplitude tresses

7.l28
 MUF.t' COUPLINGS

Equation Nomenclature

D 2 d + 13 mm D Outside diameter of sleeve

L Length of the sleeve

L 3.5 d
d Diameter of the shaft

T
1t

16
cc [ D 4~ 4]
d
T Torque transmitted by coupling

'tc 14 Mpa for C I

3.5 d L
2 2 Length of the key in each shaft

w Width of the key

d (shear failure Of key)
T 1w 't
2 Thickness of the key

r Shear stress in key

T (+) o, (+)
crc Crushing stress in key
( Crushing failure of key)

L
.I

SLEEVE OR MUFF COUPLING

SIGN DATA - PSG TECH 7.133

 /

FLANGE COUPLINGS

Equation Nomenclature

D 2d dl Nominal diameter of bolts

L 1.5 d
d Shaft diameter
DI 3 d
D Outside diameter
D2 4 d

D Diameter of bolt circle

tf (+)
n 3 for d upto 40 mrn n number of bolts

4 for d upto 100 mm

t f Thickness of flange
6 for d upto 180 mm

Thickness of protecting flange

t p (+) t p

"C
"C - N
II
H-
II a •.. N
...L...._""'--_+- _ _ _ _ _ _ IL a a
II
II
II

t~t---.;-:----~

L = 1.5 d + L = 1.5 d

UNPROTECTED TYPE FLANGE COUPLING

7.134 DESIGN DATA - PSG'TECH

 /

FLEXIBLE COUPLI G - BUSHED PIN TYPE

Equation omencJature

W Pd d 2 1 L Hub Length
Length of the bu h in the flange

T Pd d 2 In (~) d2

Pb
Diameter of bush

Bearing pressure on bush

2
r W (+) d 1
n

Dl
Number of pins
Diameter of pitch circle of pins

M W [(+) + 5] mm Pb ~ 0.5 to 0.8 v / rom

2

w Load on each pin

jL M Bending moment on pin

ap=
z a Bending stress in pin

r Shear stress in pin

0.5 d
dJ z Modulus of section of pins
{D 3
[1t /32] d I

d Shaft diameter
T 1 W "t k
(+) W Width of key

Thickness of key

tf d/2 tp = d/4
T
(+) ae (+) "t e Shear stress in flange

D Diameter of hub
T 1:5 d D= 2d

D2 PCD of pins

D2 (4t06)d
2
't (+) D "tetf
T Torque transmitted by the coupling

7.136 DESIGN DATA - PSG TEel

 /

MARINE COUPLING

Equation Nomenclature

d Shaft diameter
d
Flange thickness
3 Taken for bolt 1 is 20 to
1 is 40
1.6 d
D J PCD of bolts

D 2 Outside diameter of flange

t 't b Shear stress in bolts

Shaft diameter 35 to 55 mm 56 to 150 mm 151 to 250 mm 251 to 390 mm

No. of Bolts 4 6 8 . 10 12

Q N
Q

MARINE TYPE FLANGE COUPLING

7.138 DESIGN DATA - P G TECH

 KNUCKLE JOINT

Equation Nomenclature

dl d D Diameter of the rod

dl Diameter of the pin
d2 2d
d2 Outer Diameter of the eye
d3 1.5 d
d3 Diameter of the pin head
1.25 d
Thickness of the eye
t 1 0.75 d Thickness of the fork
t I

t 2 0.5 d t2 Thickness ofthe pin head

4.5 d 4d
'I'

Octagonal
end

Double eye or
Pin head
--.;.-- .... Single eye or
forked end rod end

d 1.1 d
d
: I :
___ +-_.L_+ __
I I I
I I I

I~
rH--+-i-- Split pin

Knuckle pin collar

Knuckle pin

KNUCKLE JOINT

ESIGN DATA - PSG TECH 7.139

 SLEEVE AND COTTER JOINT

Equation omenclaturc

dl l.3d d Diameter of the rod to be connected

b l.3d
dl Diameter of the enlarged end
d2 Outer Diameter of the sleeve
d2 2.5 d
c 1.4 d a Distance of the slot from the sleeve end
I Length of the sleeve
a 1.3 d
I Length of the cotter
e 0.5 d b Width of the cotter
L 8 d c Distance of the slot from the rod end
e Length of the enlarged end of the outside
0.3 d sleeve
4d
Thickenss of the cotter

Gib cotter

GIS AND COTTER JOINT

clearance 1.5 to 3mm

COTTERED JOINT FOR RODS

7.140 DESIGN DATA- PSG TECH