Marge Ktom Darshan PDF

Contents
1.1 Concepts of Kinematics and Dynamics .......................................................................................... 1.2

1.2 Kinematic Links ................................................................................................................................. 1.2
1.3 Types of Constrained Motions ......................................................................................................... 1.4
1.4 Kinematic Pair ................................................................................................................................... 1.5
1.5 Kinematic Chain .............................................................................................................................. 1.10
1.6 Degrees of freedom/mobility of a mechanism ............................................................................. 1.10
1.7 Inversion of Mechanism ................................................................................................................. 1.12
1.8 Four Bar Chain or Quadric Cycle Chain .......................................................................................... 1.12
1.9 Single Slider Crank Chain ................................................................................................................ 1.14
1.10 Double Slider Crank Chain .............................................................................................................. 1.17
1.11 Straight Line Mechanisms .............................................................................................................. 1.19
1.12 Problems .......................................................................................................................................... 1.24
1.1 Concepts of Kinematics and Dynamics
Kinematics: It is that branch of Theory of Machines which deals with the relative motion between the
various parts of the machines without forces applying to it.
Dynamics: It is that branch of Theory of Machines which deals with the forces and their effects while acting
upon the machine parts in motion.
Kinetics: It is that branch of Theory of Machines which deals with the inertia forces which arise from the
combined effect of the mass and motion of the machine parts.
Statics: It is that branch of Theory of Machines which deals with the forces and their effects while the
machine parts are at rest. The mass of the parts is assumed to be negligible.
Mechanism: If a number of bodies are assembled in such a way that the motion of one causes constrained
and predictable motion to the others, it is known as a mechanism.
Machine: A machine is a mechanism or a combination of mechanisms which, apart from imparting definite
motions to the parts, also transmits and modifies the available mechanical energy into some kind of
desired work.
Structure: It is an assemblage of a number of resistant bodies (known as members) having no relative
motion between them and meant for carrying loads having straining action. A railway bridge, a roof truss,
machine frames etc., are the examples of a structure.
Table 1.1 - Difference Between a Machine and a Structure
Machine Structure
Parts of a machine move relative to one another Members of a structure do not move relative to
one another
The machine transforms the available energy In a structure, no energy is transformed into useful
into some useful work work
Links of a machine may transmit both power and Members of a structure transmit forces only
motion
1.2 Kinematic Links

Each part of a machine, which moves relative to some other part, is known as a kinematic link (or simply
link). A link may consist of several parts, which are rigidly fastened together so that they do not move
relative to one another.
A link or element need not be a rigid body, but it must be a resistant body. A body is said to be a resistant
body if it is capable of transmitting the required forces with negligible deformation.
1.2.1 Types of Kinematic Links

a) Rigid Link
A rigid link is one which does not undergo any deformation while transmitting motion. Strictly speaking,
rigid links do not exist. However, as the deformation of a connecting rod, crank etc. of a reciprocating
steam engine is not appreciable, they can be considered as rigid links.
Prof. Sunil G. Janiyani, Department of Mechanical Engineering

1.2 Kinematics and Theory of Machines (3131906) |
Unit-1 Introduction of Mechanisms and Machines
Fig.1.1 - Connecting Rod
b) Flexible Link
A flexible link is one which is partly deformed in a manner not to affect the transmission of motion. For
example, belts, ropes, chains and wires are flexible links and transmit tensile forces only.
Fig.1.2 - Chain Drive
c) Fluid Link
A fluid link is one which is formed by having fluid in a receptacle and the motion is transmitted through
the fluid by pressure or compression only, as in the case of hydraulic presses, jacks and brakes.
Fig.1.3 - Hydraulic jack

Kinematics and Theory of Machines (3131906) | 1.3
1.3 Types of Constrained Motions
a) Completely Constrained Motion
When the motion between a pair is limited to a definite direction irrespective of the direction of force
applied, then the motion is said to be a completely constrained motion.
Fig.1.4 - The motion of a square bar in a square hole
Fig.1.5 - The motion of a shaft with collars at each end in a circular hole
b) Incompletely Constrained Motion

When the motion between a pair can take place in more than one direction, then the motion is called an
incompletely constrained motion. The change in the direction of the impressed force may alter the
direction of relative motion between the pair.
Fig.1.6 - A circular bar or shaft in a circular hole

c) Successfully Constrained Motion
When the motion between the elements, forming a pair, is such that the constrained motion is not
completed by itself, but by some other means, then the motion is said to be successfully constrained
motion.
Fig.1.7 - Shaft in a foot-step bearing
1.4 Kinematic Pair

The two links or elements of a machine, when in contact with each other, are said to form a pair.
If the relative motion between them is completely or successfully constrained (i.e. in a definite direction),
the pair is known as kinematic pair.
Classification of Kinematic Pairs:
1.4.1 According to the type of relative motion between the elements

a) Sliding pair
When the two elements of a pair are connected in such a way that one can only slide relative to the other,
the pair is known as a sliding pair. The piston and cylinder, cross-head and guides of a reciprocating steam
engine, ram and its guides in shaper, tail stock on the lathe bed etc. are the examples of a sliding pair. A
little consideration will show, that a sliding pair has a completely constrained motion.
 Example: Piston and Cylinder
Fig.1.8 - Piston and Cylinder

b) Turning pair
When the two elements of a pair are connected in such a way that one can only turn or revolve about a
fixed axis of another link, the pair is known as turning pair. A shaft with collars at both ends fitted into a
circular hole, the crankshaft in a journal bearing in an engine, lathe spindle supported in head stock, cycle
wheels turning over their axles etc. are the examples of a turning pair. A turning pair also has a completely
constrained motion.
 Example: Circular shaft revolving inside a bearing
Fig.1.9 Circular shaft revolving inside a bearing
c) Rolling pair
When the two elements of a pair are connected in such a way that one rolls over another fixed link, the pair
is known as rolling pair. Ball and roller bearings are examples of rolling pair.
 Example: Ball bearing
Fig.1.10 - Ball bearing
d) Screw pair
When the two elements of a pair are connected in such a way that one element can turn about the other
by screw threads, the pair is known as screw pair. The lead screw of a lathe with nut and bolt with a nut
are examples of a screw pair.

 Example: Bolt with a nut
Fig.1.11 - Bolt with a nut
e) Spherical pair
When the two elements of a pair are connected in such a way that one element (with the spherical shape)
turns or swivels about the other fixed element, the pair formed is called a spherical pair. The ball and
socket joint, attachment of a car mirror, pen stand etc., are the examples of a spherical pair.
 Example: Ball and socket joint
Fig.1.12 - Ball and socket joint
1.4.2 According to the type of contact between the elements

a) Lower pair
When the two elements of a pair have a surface contact when relative motion takes place and the surface
of one element slides over the surface of the other, the pair formed is known as lower pair.
It will be seen that sliding pairs, turning pairs and screw pairs form lower pairs.
 Example: A square bar in a square hole
Fig.1.13 - Types of lower pair
b) Higher pair
When the two elements of a pair have a line or point contact when relative motion takes place and the
motion between the two elements is partly turning and partly sliding, then the pair is known as higher pair.
A pair of friction discs toothed gearing, belt and rope drives, ball and roller bearings and cam and follower
are the examples of higher pairs.
 Example: Cam and Follower
Fig.1.14 - Cam and Follower

1.4.3 According to the type of closure
a) Self closed pair
When the two elements of a pair are connected together mechanically in such a way that only required
kind of relative motion occurs, it is then known as self-closed pair. The lower are self-closed pair.
 Example: Bolt with a nut
Fig.1.15 - Bolt with a nut
b) Force - closed pair

When the two elements of a pair are not connected mechanically but are kept in contact by the action of
external forces, the pair is said to be a force-closed pair. The cam and follower is an example of force
closed pair, as it is kept in contact by the forces exerted by spring and gravity.
 Example: Cam and follower with spring
Fig.1.16 - Cam and follower with spring

1.5 Kinematic Chain
When the kinematic pairs are coupled in such a way that the last link is joined to the first link to transmit
definite motion (i.e. completely or successfully constrained motion), it is called a kinematic chain.
In other words, a kinematic chain may be defined as a combination of kinematic pairs, joined in such a
way that each link forms a part of two pairs and the relative motion between the links or elements is
completely or successfully constrained.
For example, the crankshaft of an engine forms a kinematic pair with the bearings which are fixed in a pair,
the connecting rod with the crank forms a second kinematic pair, the piston with the connecting rod forms
a third pair and the piston with the cylinder forms the fourth pair. The total combination of these links is a
kinematic chain.
Table 1.2 - Difference Between Kinematic Pair and Kinematic Chain
Kinematic Pair Kinematic Chain
Two elements connected together Four or more than four elements connected
together
Have constrained relative motion with respect to The motion of any point on the link with respect to
each other any other point follows a definite direction
Each pair has two links The chain has minimum four links. The first link
and last link are connected to form a closed chain
Kinematic pair is a part of the chain. Kinematic Chain is not a part of the Kinematic pair.
Examples: Examples:
1. Cylinder and Piston 1. Four bar chain
2. Crank and connecting rod 2. Slider crank chain
3. Piston and connecting rod 3. Double crank chain
 When one of the links of a kinematic chain is fixed, the chain is known as a mechanism. It may be
used for transmitting or transforming motion e.g. engine indicators, typewriter etc.
 A mechanism with four links is known as a simple mechanism.
 A mechanism with more than four links is known as a compound mechanism.
 When a mechanism is required to transmit power or to do some particular type of work, it then
becomes a machine.
In such cases, the various links or elements have to be designed to withstand the forces (both static and
kinetic) safely. A little consideration will show that a mechanism may be regarded as a machine in which
each part is reduced to the simplest form to transmit the required motion.
1.6 Degrees of freedom/mobility of a mechanism

It is the number of inputs (number of independent coordinates) required to describe the configuration or
position of all the links of the mechanism, with respect to the fixed link at any given instant.

1.6.1 Kutzbach Criterion to Plane Mechanisms
Kutzbach criterion is used for determining the number of degrees of freedom or movability (n) of a plane
mechanism.
𝑛 = 3 (𝑙 – 1) – 2 𝑗 – ℎ Eq. (1.1)
where,
n = Number of degrees of freedom;
j = Number of binary joints;
h = Number of higher pairs;
l = Number of links
Fig.1.17 - Plane mechanisms
1. The mechanism, as shown in (a), has three links and three binary joints, i.e. l = 3 and j = 3.
n = 3 (3 – 1) – 2 × 3 = 0
2. The mechanism, as shown in (b), has four links and four binary joints, i.e. l = 4 and j = 4.
n = 3 (4 – 1) – 2 × 4 = 1
3. The mechanism, as shown in (c), has five links and five binary joints, i.e. l = 5, and j = 5.
n = 3 (5 – 1) – 2 × 5 = 2
1.6.2 Grubler’s Criterion for Plane Mechanisms

The Grubler’s criterion applies to mechanisms with an only single degree of freedom joints where the
overall movability of the mechanism is unity. Substituting n = 1 and h = 0 in Kutzbach equation, we have
1 = 3 (l – 1) – 2 j
 3l – 2j – 4 = 0
This equation is known as the Grubler's criterion for plane mechanisms with constrained motion.
A little consideration will show that a plane mechanism with a movability of 1 and only a single degree of
freedom joints can’t have odd number of links. The simplest possible mechanisms of this type are a four-
bar mechanism and a slider-crank mechanism in which l = 4 and j = 4.

1.7 Inversion of Mechanism
When one of the links is fixed in a kinematic chain, it is called a mechanism. So we can obtain as many
mechanisms as the number of links in a kinematic chain by fixing, in turn, different links in a kinematic
chain. This method of obtaining different mechanisms by fixing different links in a kinematic chain is
known as inversion of the mechanism.
It may be noted that the relative motions between the various links are not changed in any manner through
the process of inversion, but their absolute motions (those measured with respect to the fixed link) may
be changed drastically.
1.7.1 Types of Kinematic Chains

The most important kinematic chains are those which consist of four lower pairs, each pair being a sliding
pair or a turning pair. The following three types of kinematic chains with four lower pairs are important:
1. Four bar chain or quadric cyclic chain
2. Single slider crank chain
3. Double slider crank chain
1.8 Four Bar Chain or Quadric Cycle Chain

The simplest and the basic kinematic chain is a four-bar chain or quadric cycle chain. It consists of four
links, each of them forms a turning pair at A, B, C and D. The four links may be of different lengths.
According to Grashof ’s law for a four-bar mechanism, the sum of the shortest and longest link lengths
should not be greater than the sum of the remaining two link lengths if there is to be continuous relative
motion between the two links.
Fig.1.18 - Four Bar Chain
In a four-bar chain, one of the links, in particular the shortest link, will make a complete revolution relative
to the other three links, if it satisfies the Grashof ’s law. Such a link is known as crank or driver.
AD (link 4) is a crank. The link BC (link 2) which makes a partial rotation or oscillates is known as lever or
rocker or follower and the link CD (link 3) which connects the crank and lever is called connecting rod or
coupler. The fixed link AB (link 1) is known as the frame of the mechanism.

1.8.1 Inversions of Four Bar Chain
Though there are many inversions of the four-bar chain, yet the following are important:
1.8.1.1 Beam engine (crank and lever mechanism)

A part of the mechanism of a beam engine (also known as crank and lever mechanism) which consists of
four links.
In this mechanism, when the crank rotates about the fixed centre A, the lever oscillates about a fixed centre
D. The end E of the lever CDE is connected to a piston rod which reciprocates due to the rotation of the
crank. In other words, the purpose of this mechanism is to convert rotary motion into reciprocating motion.
Fig.1.19 - Beam engine
1.8.1.2 Coupling rod of a locomotive (Double crank mechanism)

The mechanism of a coupling rod of a locomotive (also known as a double crank mechanism) which
consists of four links.
In this mechanism, the links AD and BC (having equal length) act as cranks and are connected to the
respective wheels. The link CD acts as a coupling rod and the link AB is fixed in order to maintain a constant
centre to centre distance between them.
This mechanism is meant for transmitting rotary motion from one wheel to the other wheel.
Fig.1.20 - Coupling rod of a locomotive

1.8.1.3 Watt’s indicator mechanism (Double lever mechanism)
A Watt’s indicator mechanism (also known as Watt's straight-line mechanism or double lever mechanism)
which consists of four links.
The four links are fixed link at A, link AC, link CE and link BFD. It may be noted that BF and FD form one link
because these two parts have no relative motion between them. The links CE and BFD act as levers. The
displacement of the link BFD is directly proportional to the pressure of gas or steam which acts on the
indicator plunger.
On any small displacement of the mechanism, the tracing point E at the end of the link CE traces out
approximately a straight line.
Fig.1.21 - Watt's straight-line mechanism
1.9 Single Slider Crank Chain

A single slider crank chain is a modification of the basic four-bar chain. It consists of one sliding pair and
three turning pairs. It is usually, found in reciprocating steam engine mechanism. This type of mechanism
converts rotary motion into reciprocating motion and vice versa.
In a single slider crank chain, the links 1 and 2, links 2 and 3, and links 3 and 4 form three turning pairs
while the links 4 and 1 form a sliding pair. The link 1 corresponds to the frame of the engine, which is fixed.
The link 2 corresponds to the crank; link 3 corresponds to the connecting rod and link 4 corresponds to
cross-head. As the crank rotates, the cross-head reciprocates in the guides and thus the piston
reciprocates in the cylinder.
Fig.1.22 - Single slider crank chain

1.9.1 Inversions of Single Slider Crank Chain
Following are the Inversions of Single Slider Crank Chain:
1.9.1.1 Pendulum pump or Bull engine

In this mechanism, the inversion is obtained by fixing the cylinder or link 4 (i.e. sliding pair).
In this case, when the crank (link 2) rotates, the connecting rod (link 3) oscillates about a pin pivoted to
the fixed link 4 at A and the piston attached to the piston rod (link 1) reciprocates.
 Application: The duplex pump which is used to supply feed water to boilers have two pistons
attached to link 1.
Fig.1.23 - Pendulum pump
1.9.1.2 Oscillating cylinder engine

The arrangement of the oscillating cylinder engine mechanism is used to convert reciprocating motion
into rotary motion. In this mechanism, the link 3 forming the turning pair is fixed.
Link 3 corresponds to the connecting rod of a reciprocating steam engine mechanism. When the crank
(link 2) rotates, the piston attached to piston rod (link 1) reciprocates and the cylinder (link 4) oscillates
about a pin pivoted to the fixed link at A.
Fig.1.24 - Oscillating cylinder engine

1.9.1.3 Rotary internal combustion engine or Gnome engine
It consists of seven cylinders in one plane and all revolves about fixed centre D, while the crank (link 2) is
fixed. In this mechanism, when the connecting rod (link 4) rotates, the piston (link 3) reciprocates inside
the cylinders forming link 1.
 Application: Sometimes back, rotary internal combustion engines were used in aviation. But
nowadays gas turbines are used in its place.
Fig.1.25 - Rotary internal combustion engine
1.9.1.4 Crank and slotted lever quick return motion mechanism

In this mechanism, the link AC (i.e. link 3) forming the turning pair is fixed. Link 3 corresponds to the
connecting rod of a reciprocating steam engine.
The driving crank CB revolves with uniform angular speed about the fixed centre C. A sliding block attached
to the crank pin at B slides along the slotted bar AP and thus causes AP to oscillate about the pivoted
point A. A short link PR transmits the motion from AP to the ram which carries the tool and reciprocates
along the line of stroke R1 R2. The line of stroke of the ram (i.e. R1 R2) is perpendicular to AC produced.
 Application: This mechanism is mostly used in shaping machines
Fig.1.26 - Crank and slotted lever quick return motion mechanism

1.9.1.5 Whitworth quick return motion mechanism
In this mechanism, the link CD (link 2) forming the turning pair is fixed. Link 2 corresponds to a crank in a
reciprocating steam engine.
The driving crank CA (link 3) rotates at a uniform angular speed. The slider (link 4) attached to the crank
pin at A slides along the slotted bar PA (link 1) which oscillates at a pivoted point D. The connecting rod
PR carries the ram at R to which a cutting tool is fixed. The motion of the tool is constrained along the line
RD produced, i.e. along a line passing through D and perpendicular to CD.
 Application: This mechanism is mostly used in and slotting machines
Fig.1.27 - Whitworth quick return motion mechanism
Table 1.3 - Inversions of single slider crank chain and their application
Mechanism Application
Pendulum pump or Bull engine Duplex pump - supply feed water to boilers
Oscillating cylinder engine Reciprocating steam engine
Rotary internal combustion engine or Gnome engine Used in aviation
Crank and slotted lever quick return motion mechanism Mostly used in shaping machines
Whitworth quick return motion mechanism Mostly used in slotting machines
1.10 Double Slider Crank Chain

A kinematic chain which consists of two turning pairs and two sliding pairs is known as a double slider
crank chain.
1.10.1 Inversions of Double Slider Crank Chain

Following are the Inversions of Double Slider Crank Chain:

1.10.1.1 Elliptical trammels
This inversion is obtained by fixing the slotted plate (link 4).
The fixed plate or link 4 has two straight grooves cut in it, at right angles to each other. Link 1 and link 3,
are known as sliders and form sliding pairs with link 4.
The link AB (link 2) is a bar which forms turning pair with links 1 and 3. When the links 1 and 3 slides along
their respective grooves, any point on link 2 such as P traces out an ellipse on the surface of link 4.
 Application: It is an instrument used for drawing ellipses
Fig.1.28 - Elliptical trammels
1.10.1.2 Scotch yoke mechanism

The inversion is obtained by fixing either the link 1 or link 3. Link 1 is fixed.
In this mechanism, when the link 2 (which corresponds to crank) rotates about B as centre, the link 4
(which corresponds to a frame) reciprocates. The fixed link 1 guides the frame.
 Application: This mechanism is used for converting rotary motion into a reciprocating motion
Fig.1.29 - Scotch yoke mechanism

1.10.1.3 Oldham’s coupling
The shafts are coupled in such a way that if one shaft rotates, the other shaft also rotates at the same
speed. This inversion is obtained by fixing the link 2. The shafts to be connected have two flanges (link 1
and link 3) rigidly fastened at their ends by forging.
 Application: It is used for connecting two parallel shafts whose axes are at a small distance apart
Fig.1.30 - Oldham’s coupling
1.11 Straight Line Mechanisms

One of the most common forms of the constraint mechanisms is that it permits only the relative motion
of an oscillatory nature along a straight line. The mechanisms used for this purpose are called straight-
line mechanisms. These mechanisms are of the following two types:
1. in which only turning pairs are used, and
2. in which one sliding pair is used.
These two types of mechanisms may produce exact straight-line motion or approximate straight-line
motion.
The principle adopted for a mathematically correct or exact straight-line motion is described in following
figure. Let O be a point on the circumference of a circle of diameter OP.
Let OA be any chord and B is a point on OA produced, such that OA × OB = constant. Then the locus of a
point B will be a straight line perpendicular to the diameter OP.
Fig.1.31 - Exact straight line motion mechanism

1.11.1 Exact Straight Line Motion Mechanisms
Following are some important Exact Straight Line Motion Mechanisms:
1.11.1.1 Peaucellier mechanism

It consists of a fixed link OO1 and the other straight links O1A, OC, OD, AD, DB, BC and CA are connected
by turning pairs at their intersections. The pin at A is constrained to move along the circumference of a
circle with the fixed diameter OP, by means of the link O 1A.
AC = CB = BD = DA; OC = OD; and OO 1 = O1A
Fig.1.32 - Peaucellier mechanism
1.11.1.2 Hart’s mechanism

This mechanism requires only six links as compared with the eight links required by the Peaucellier
mechanism.
It consists of a fixed link OO1 and other straight links O1A, FC, CD, DE and EF are connected by turning pairs
at their points of intersection.
FC = DE; CD = EF;
The points O, A and B divide the links FC, CD and EF in the same ratio. A little consideration will show that
BOCE is a trapezium and OA and OB are respectively parallel to FD and CE. Hence OAB is a straight line.
Fig.1.33 - Hart’s mechanism

1.11.1.3 Scott Russell’s Mechanism
It consists of a fixed member and moving member P of a sliding pair. The straight link PAQ is connected
by turning pairs to the link OA and the link P. The link OA rotates about O.
A little consideration will show that the mechanism OAP is the same as that of the reciprocating engine
mechanism in which OA is the crank and PA is the connecting rod.
In this mechanism, the straight-line motion is not generated but it is merely copied.
Fig.1.34 - Scott Russell’s Mechanism
1.11.2 Approximate Straight Line Motion Mechanisms

The approximate straight-line motion mechanisms are the modifications of the four-bar chain
mechanisms. Following are the important mechanisms to give approximate straight-line motion.
1.11.2.1 Watt’s mechanism

It is a crossed four-bar chain mechanism and was used by Watt for his early steam engines to guide the
piston rod in a cylinder to have an approximately straight-line motion.
OBAO1 is a crossed four-bar chain in which O and O1 are fixed. In the mean position of the mechanism,
links OB and O1A are parallel and the coupling rod AB is perpendicular to O1A and OB.
The tracing point P traces out an approximately straight line over certain positions of its movement, if
PB/PA= O1A/OB
Fig.1.35 - Watt’s mechanism

1.11.2.2 Modified Scott-Russel mechanism
This mechanism is similar to Scott-Russel mechanism, but in this case, AP is not equal to AQ and the
points P and Q are constrained to move in the horizontal and vertical directions.
A little consideration will show that it forms an elliptical trammel so that any point A on PQ traces an ellipse
with semi-major axis AQ and semi-minor axis AP.
If the point A moves in a circle, then for point Q to move along an approximate straight line, the length OA
must be equal (AP)2 / AQ
Fig.1.36 - Modified Scott-Russel mechanism
1.11.2.3 Grasshopper mechanism

This mechanism is a modification of modified Scott-Russel’s mechanism with the difference that the point
P does not slide along a straight line but moves in a circular arc with centre O. It is a four-bar mechanism
and all the pairs are turning pairs
In this mechanism, the centres O and O1 are fixed. The link OA oscillates about O through an angle AOA 1
which causes the pin P to move along a circular arc with O 1 as centre and O1P as radius.
The Grasshopper mechanism was used in early days as an engine mechanism which gave long stroke
with a very short crank.
Fig.1.37 - Grasshopper mechanism

1.11.2.4 Tchebicheff’s mechanism
It is a four-bar mechanism in which the crossed links OA and O 1B are of equal length. The point P, which
is the mid-point of AB traces out an approximately straight line parallel to OO 1.
The proportions of the links are, usually, such that point P is exactly above O or O 1 in the extreme positions
of the mechanism i.e. when BA lies along OA or when BA lies along BO1.
It may be noted that the point P will lie on a straight line parallel to OO 1, in the two extreme positions and
in the mid position, if the lengths of the links are in proportions AB: OO1: OA = 1: 2: 2.5.
Fig.1.38 - Tchebicheff’s mechanism
1.11.2.5 Roberts mechanism

It is also a four-bar chain mechanism, which, in its mean position, has the form of a trapezium. The links
OA and O1B are of equal length and OO1 is fixed.
A bar PQ is rigidly attached to the link AB at its middle point P. A little consideration will show that if the
mechanism is displaced as shown by the dotted lines, the point Q will trace out an approximately straight
line.
Fig.1.39 - Roberts mechanism

1.12 Problems
Ex. 1.1 [GTU; June-2016; 7 Marks] [GTU; Jan.-2016; 4 Marks]
A crank and slotted lever mechanism used in a shaper has a centre distance of 300 mm
between the centre of oscillation of the slotted lever and the centre of rotation of the crank.
The radius of the crank is 120 mm. Find the ratio of the time of cutting to the time of return
stroke.
Solution: Given Data: To be Calculated:
𝐴𝐶 = 300 𝑚𝑚 The ratio of time of
cutting to time of return
𝐶𝐵1 = 120 mm
stroke
 The extreme positions of the crank are shown in Figure. We know that,
𝛼 𝐶𝐵1 120
𝑆𝑖𝑛 ∠𝐶𝐴𝐵1 = 𝑆𝑖𝑛 (90° − )= = = 0.4
2 𝐴𝐶 300
𝛼
∴ ∠𝐶𝐴𝐵1 = (90° − ) = sin−1 (0.4) = 23.6°
2
𝛼
∴ = (90° − 23.6°) = 66.4°
2
∴ 𝛼 = 2 × 66.4° = 132.8°
𝑻𝒊𝒎𝒆 𝒐𝒇 𝒄𝒖𝒕𝒕𝒊𝒏𝒈 𝒔𝒕𝒓𝒐𝒌𝒆 360°− 𝛼 360°−132.8°
 = = = 1.72
𝐓𝐢𝐦𝐞 𝐨𝐟 𝐫𝐞𝐭𝐮𝐫𝐧 𝐬𝐭𝐫𝐨𝐤𝐞 𝛼 132.8°
Ex. 1.2 In a crank and slotted lever quick return motion mechanism, the distance between the fixed
centres is 240 mm and the length of the driving crank is 120 mm. Find the time ratio of
cutting stroke to the return stroke. If the length of the slotted bar is 450 mm, find the length
of the stroke if the line of stroke passes through the extreme positions of the free end of the
lever.
Solution: Given Data:
𝐴𝐶 = 240 𝑚𝑚
𝐶𝐵1 = 120 mm
𝐴𝑃1 = 450 mm
To be Calculated:
a) The ratio of time of
cutting stroke to
time of return stroke
b) Length of stroke

 The extreme positions of the crank are shown in Figure. We know that,
𝛼 𝐶𝐵1 120
𝑆𝑖𝑛 ∠𝐶𝐴𝐵1 = 𝑆𝑖𝑛 (90° − )= = = 0.5
2 𝐴𝐶 240
𝛼
∴ ∠𝐶𝐴𝐵1 = (90° − ) = sin−1(0.5) = 30°
2
𝛼
∴ = (90° − 30°) = 60°
2
∴ 𝛼 = 2 × 60° = 120°
𝑻𝒊𝒎𝒆 𝒐𝒇 𝒄𝒖𝒕𝒕𝒊𝒏𝒈 𝒔𝒕𝒓𝒐𝒌𝒆 360°− 𝛼 360°−120°
 = = =2
𝐓𝐢𝐦𝐞 𝐨𝐟 𝐫𝐞𝐭𝐮𝐫𝐧 𝐬𝐭𝐫𝐨𝐤𝐞 𝛼 120°
 Length of the stroke,
𝛼
𝑅1 𝑅2 = 𝑃1 𝑃2 = 2𝑃1 𝑄 = 2 × 𝐴𝑃1 × 𝑆𝑖𝑛 (90° − )
2
∴ 𝐋𝐞𝐧𝐠𝐭𝐡 𝐨𝐟 𝐒𝐭𝐫𝐨𝐤𝐞 = 2 × 450 × 𝑆𝑖𝑛 (90° − 60°) = 900 × 0.5 = 𝟒𝟓𝟎 𝒎𝒎
References:
1. Theory of Machines, Rattan S S, Tata McGraw-Hill
2. Theory of Machines and Mechanisms, Uicker J J Jr., Pennock G R, Shigley J E, Oxford Press
3. Theory of Machines, Khurmi R. S., Gupta J. K., S. Chand Publication

Contents
2.1 Synthesis of Mechanisms ................................................................................................................ 2.2

2.2 Freudenstein’s Equation (Synthesis a four-bar mechanism) ......................................................... 2.3
2.3 Two-Position Synthesis of Slider-Crank Mechanisms.................................................................... 2.4
2.4 Two Position Synthesis of Crank and Rocker Mechanism ............................................................ 2.5
2.5 Inversion Method of Synthesis for Four-Bar Mechanism using Three Point ................................ 2.7
2.6 Chebychev Spacing for Precision Positions ................................................................................... 2.8
2.7 Problems ............................................................................................................................................ 2.9
2.1 Synthesis of Mechanisms
The synthesis of the mechanism is the design or creation of a mechanism to produce the desired output
motion for a given input motion. In other words, the synthesis of mechanism deals with the determination
of proportions of a mechanism for the given input and output motion.
In the application of synthesis, to the design of a mechanism, the problem divides itself into the following
three parts:
 Type synthesis: Type Synthesis refers to the kind of mechanism selected; it might be a linkage, a
geared system, belts, and pulleys, or even a cam system.
This beginning phase of the total design problem usually involves design factors such as
manufacturing processes, materials, safety space and economics. The study of kinematics is
usually only slightly involved in type synthesis.
 Number synthesis: Number synthesis deals with the number of links, and the number of joints or
pairs that are required to obtain certain mobility. Number synthesis is the second step in design
following type synthesis.
 Dimensional synthesis: The proportions or lengths of the links necessary to satisfy the required
motion characteristics.
In designing a mechanism, one factor that must be kept in mind is that of the accuracy required of the
mechanism. Sometimes, it is possible to design a mechanism that will theoretically generate a given
motion. The difference between the desired motion and the actual motion produced is known as structural
error.
In addition to this, there are errors due to manufacturing. The error resulting from tolerances in the length
of links and bearing clearances is known as mechanical error.
2.1.1 Classifications of Synthesis Problem

a) Function Generation
A frequent requirement in design is that of causing an output member to rotate, oscillate or reciprocate
according to a specified function of time or function of input motion. This is called function generation.
A simple example is that of synthesizing a four-bar linkage to generate the function y=f(x). In this case, x
would represent the motion (crank angle) of input crank, and the linkage would be designed so that the
motion (angle) of the output rocker would approximate the function y.
Other examples of function generation are as follows:
1. In a conveyor line the output member of a mechanism must move at the constant velocity of the
conveyor while performing some operations – Ex. bottle capping, return, pick up the next cap and
repeat the operation.
2. The output member must pause or stop during its motion cycle to provide time for another event.
The second event might be a sealing, stapling, or fastening operation of some kind.
3. The output member must rotate at a specified non-uniform velocity function because it is geared
to another mechanism that requires such a rotating motion.
b) Path Generation:
The second type of synthesis problem is called path generation. This refers to a problem in which a coupler
point is to generate a path having a prescribed shape. Common requirements are that a portion of the path
is a circular arc, elliptical or straight line. Sometimes it is required that the path cross over itself as in a
figure-of-eight.
Unit-2 Graphical and Analytical Linkage Synthesis
c) Body Guidance:
The third general class of synthesis problem is called body guidance. Here we are interested in moving an
object from one position to another.
The problem may call for a simple translation or a combination of translation and rotation (JCB example).
In the construction industry, for example, heavy parts such as scoops and bulldozer blades must be moved
through a series of prescribed positions.
2.2 Freudenstein’s Equation (Synthesis a four-bar mechanism)
Fig.2.1 – Four bar mechanism
 Replace the link of four-bar linkage by position vector and write the vector equation.
𝑟1 + 𝑟2 + 𝑟3 + 𝑟4 = 0
In complex polar notation above equation can be written as
𝑟1 𝑒 𝑗𝜃1 + 𝑟2 𝑒 𝑗𝜃2 + 𝑟3 𝑒 𝑗𝜃3 + 𝑟4 𝑒 𝑗𝜃4 = 0
Above equation is transformed into complex rectangular form by putting
𝒆𝒋𝜽 = 𝐜𝐨𝐬 𝜽 + 𝒋 ∙ 𝐬𝐢𝐧 𝜽.
∴ 𝑟1 ( cos 𝜃1 + 𝑗 ∙ sin 𝜃1 ) + 𝑟2 ( cos 𝜃2 + 𝑗 ∙ sin 𝜃2 ) + 𝑟3 ( cos 𝜃3 + 𝑗 ∙ sin 𝜃3 ) + 𝑟4 ( cos 𝜃4 + 𝑗 ∙ sin 𝜃4 ) = 0
 Now, if the real and imaginary components of the above equation are separated, we obtain the two
algebraic equations
𝑟1 cos 𝜃1 + 𝑟2 cos 𝜃2 + 𝑟3 cos 𝜃3 + 𝑟4 cos 𝜃4 = 0
𝑟1 sin 𝜃1 + 𝑟2 sin 𝜃2 + 𝑟3 sin 𝜃3 + 𝑟4 sin 𝜃4 = 0
In the above equation 𝐬𝐢𝐧 𝜽𝟏 = 𝟎 and 𝐜𝐨𝐬 𝜽𝟏 = −𝟏
∴ −𝑟1 + 𝑟2 cos 𝜃2 + 𝑟3 cos 𝜃3 + 𝑟4 cos 𝜃4 = 0
𝑟2 sin 𝜃2 + 𝑟3 sin 𝜃3 + 𝑟4 sin 𝜃4 = 0

 Now,
∴ 𝑟3 cos 𝜃3 = 𝑟1 − 𝑟2 cos 𝜃2 − 𝑟4 cos 𝜃4
∴ 𝑟3 sin 𝜃3 = −𝑟2 sin 𝜃2 − 𝑟4 sin 𝜃4
 Squaring and Adding both the equations
𝑟32 (cos 2 𝜃3 + sin2 𝜃3 ) = (𝑟1 − 𝑟2 cos 𝜃2 − 𝑟4 cos 𝜃4 )2 + (−𝑟2 sin 𝜃2 − 𝑟4 sin 𝜃4 )2

∴ 𝑟32 = (𝑟1 − 𝑎)2 + (−𝑟2 sin 𝜃2 − 𝑟4 sin 𝜃4 )2
= 𝑟12 − 2𝑎𝑟1 + 𝑎2 + 𝑟22 sin2 𝜃2 + 2𝑟2 𝑟4 sin 𝜃2 sin 𝜃4 + 𝑟42 sin2 𝜃4
= 𝑟12 − 2(𝑟2 cos 𝜃2 + 𝑟4 cos 𝜃4 )𝑟1 + (𝑟2 cos 𝜃2 + 𝑟4 cos 𝜃4 )2 + 𝑟22 sin2 𝜃2 + 2𝑟2 𝑟4 sin 𝜃2 sin 𝜃4
+ 𝑟42 sin2 𝜃4
= 𝑟12 − 2𝑟1 𝑟2 cos 𝜃2 − 2𝑟1 𝑟4 cos 𝜃4 + 𝑟22 cos2 𝜃2 + 2𝑟2 𝑟4 cos 𝜃2 cos 𝜃4 + 𝑟42 cos2 𝜃4 + 𝑟22 sin2 𝜃2
+ 2𝑟2 𝑟4 sin 𝜃2 sin 𝜃4 + 𝑟42 sin2 𝜃4
= 𝑟12 + 𝑟22 + 𝑟42 − 2𝑟1 𝑟2 cos 𝜃2 − 2𝑟1 𝑟4 cos 𝜃4 + 2𝑟2 𝑟4 (cos 𝜃2 cos 𝜃4 + sin 𝜃2 sin 𝜃4 )
∴ 𝑟32 − 𝑟12 − 𝑟22 − 𝑟42 + 2𝑟1 𝑟2 cos 𝜃2 + 2𝑟1 𝑟4 cos 𝜃4 = 2𝑟2 𝑟4 cos(𝜃2 − 𝜃4 )
 Dividing both the sides by 2r2r4
𝑟32 − 𝑟12 − 𝑟22 − 𝑟42 𝑟1 𝑟1

∴ + cos 𝜃2 + cos 𝜃4 = cos(𝜃2 − 𝜃4 )
2𝑟2 𝑟4 𝑟4 𝑟2
𝐾1 cos 𝜃2 + 𝐾2 cos 𝜃4 + 𝐾3 = cos(𝜃2 − 𝜃4 )
Where
𝑟1 𝑟1 𝑟32 − 𝑟12 − 𝑟22 − 𝑟42

𝐾1 = , 𝐾2 = , 𝐾3 =
𝑟4 𝑟2 2𝑟2 𝑟4
 Freudenstein’s equation enables us to perform this same task by analytical means. Thus suppose
we wish the output lever of a four-bar linkage to occupy the position ∅1 , ∅2 , and ∅3 corresponding
to the angular positions 𝜓1 , 𝜓2 , and 𝜓3 of the input lever. We simply replace 𝜃2 with 𝜓𝑖 , 𝜃4 with ∅𝑖 ,
and write the equation three times, once for each position.
𝐾1 cos 𝜓1 + 𝐾2 cos 𝜙1 + 𝐾3 = cos(𝜓1 − 𝜙1 )

2.3 Two-Position Synthesis of Slider-Crank Mechanisms

The centered slider-crank mechanism has a stroke B1B2 equal to twice the crank radius r2 (B1B2 = 2r2). As
shown, the extreme positions of B1 and B2, also called limiting positions of the slider, are found by
constructing circular arcs through O2 of length (r3 - r2) and (r3 + r2), respectively.
In general, the centered slider-crank mechanism must have r3 > r2. However, the special case of r1 = r2
results in the isosceles slider-crank mechanism, in which the slider reciprocates through O2 and the stroke
4 × r2.
Fig.2.2 – Centered slider-crank mechanism
Fig.2.3 – General or offset slider crank mechanism

All points on the coupler of the isosceles slider-crank mechanism generate elliptical paths. The paths
generated by the points on the coupler of the slider-crank are not elliptical, but they are always symmetrical
about the axis O2B.
The linkage of general or offset slider-crank mechanism certain special effects can be obtained by
changing the offset distance e. Ex. the stroke B1B2 is always greater than 2 × crank radius r2.
This feature can be used to synthesize a quick return mechanism where a slower working stroke is desired.
Also, the crank angle required to execute the forward stroke is different from that of the return stroke.
2.4 Two Position Synthesis of Crank and Rocker Mechanism

The limiting positions of the rocker in a crank and rocker mechanism are shown as points B1 and B2 (Found
same as slider-crank linkage).
In this particular case, the crank executes the angle Ψ while the rocker moves from B 1 to B2. Note on the
return stroke that the rocker swing from B2 to B1 through the same angle but the crank moves through the
angle (360° – Ψ).
Fig.2.4 - Extreme Position of Crank and Rocker Mechanism
There are many cases in which the crank and rocker mechanism is superior to the cam and follower
system. Among the advantages over the cam, the system is smaller forces involved, the elimination of
retaining spring, and the closer clearance because of the use of revolute pairs.
Cutting stroke B2 to B1 (∅ angle on the rocker) Ψ angle on the crank
Return stroke B1 to B2 (∅ angle on the rocker) 360° – Ψ angle on the crank
𝜓
𝜓 180 + 𝛼 𝑡1 =
𝑄= = { 𝜔 }
2𝜋 − 𝜓 180 − 𝛼 360 − 𝜓 2𝜋 − 𝜓
𝑡2 = =
𝜔 𝜔
Fig.2.5 - Synthesis of a four-bar linkage to generate rocker angle ∅

To synthesis, a crank and rocker mechanism for a specified value of ∅ and 𝛼, locate the point O4 in the
figure and choose any desired rocker length r 4, then draw the two positions O4B1 and O4B2 of link 4
separated by the angle ∅ as given.
Through B1 construct any line X Then through B2 construct the line Y at given angle 𝛼 to line X. The
intersection of these two lines defines the location of the crank pivot O 2. Because line X was originally
chosen arbitrarily, there is an infinite number of solutions to this problem.
The distance B2C is 2r2 or twice the crank length. So we bisect this distance to find r 2.

2.5 Inversion Method of Synthesis for Four-Bar Mechanism using Three Point
 In the below figure, the motion of input rocker O2A through the angle 𝜓12 causes the motion of the
output rocker O4B through angle ∅12.
Fig.2.6 - Rotation of input rocker O2A through the angle ψ12 cause rocker O4B to rock through the angle ∅12
 To employ inversion as a technique of synthesis, let us hold O 4B stationary and permit the
remaining links, including the frame, to occupy the same relative positions.
 The result is called inverting on the output rocker. Note that A 1B1 is positioned the same in the
below figure. Therefore the inversion is made on the O4B1 position. Because O4B1is fixed, the frame
will have to move in order to get the linkage to the A 2B2 position. In fact, the frame must move
backward through the angle ∅12. The second position is therefore O′2 A′2 B2′ O4.
Fig.2.7 - Linkage inverted on the O4B position
 The below figure illustrates a problem and the synthesized linkage in which it is desired to
determine the dimensions of a linkage in which the output lever is to occupy three specified
positions corresponding to three given positions of input lever.
 The starting angle of the input lever is 𝜃2; and 𝜓12, 𝜓23, and 𝜓13 are swing angle respectively between
the three design positions 1 and 2, 2 and 3, and 1 and 3. Corresponding angles of swing ∅12, ∅23 and
∅13 are desired for the output lever. The length of link 4 and the starting position O4 are to be
determined.

Fig.2.8 – Three positions of input lever and output lever
2.6 Chebychev Spacing for Precision Positions
Fig.2.9 - Structural Error
 We need to work with two or three or four positions of the linkage called precision positions and to
find a linkage that exactly satisfies the desired function at a few chosen positions.
 Structural error is defined as the theoretical difference between the function produced by the
synthesized linkage and the function originally prescribed.
 A very good trial for the spacing of these precision positions is called Chebychev spacing. For n
precision position in the range 𝑥0 ≤ 𝑥 ≤ 𝑥𝑛+1 , the Chebychev spacing according to Freudenstein
and Sandor, is
1 1 (2𝑗 − 1)𝜋
𝑥𝑗 = (𝑥𝑛+1 + 𝑥0 ) − (𝑥𝑛+1 − 𝑥0 )𝑐𝑜𝑠
2 2 2𝑛
Where 𝑗 = 1,2, … 𝑛 And n = No. of precision positions

2.7 Problems
Ex. 2.1 [GTU; June-2016; 7 Marks] [GTU; Jan.-2016; 7 Marks]
A four-bar mechanism is to be designed, by using three precision points, to generate the
function
y = x1.5, for the range 1 x 4 .
Assuming 30° starting position and 120° finishing position for the input link and
90°starting position and 180° finishing position for the output link, find the values of x, y,
 and φ corresponding to the three precision points.
xS = 1; xF = 4; s= 30; F = 120; φS = 90 and φF = 180
The three values of x corresponding to three precision points (i.e. for n = 3) according to
Chebychev’s spacing are given by,
𝟏 𝟏 (𝟐𝒋 − 𝟏)𝝅
𝒙𝒋 = (𝒙𝑭 + 𝒙𝑺 ) − (𝒙𝑭 − 𝒙𝑺 ) (𝒄𝒐𝒔 [ ])
𝟐 𝟐 𝟐𝒏
1 1 (2𝑗 − 1)𝜋
∴ 𝑥𝑗 = (4 + 1) − (4 − 1) (𝑐𝑜𝑠 [ ])
2 2 2(3)
(𝟐𝒋 − 𝟏)𝝅
∴ 𝒙𝒋 = 𝟐. 𝟓 − 𝟏. 𝟓 (𝒄𝒐𝒔 [ ])
𝟔
For j = 1,
(2(1) − 1)𝜋
𝑥1 = 2.5 − 1.5 (𝑐𝑜𝑠 [ ])
6
𝜋
∴ 𝑥1 = 2.5 − 1.5 (𝑐𝑜𝑠 [ ])
6
∴ 𝑥1 = 2.5 − 1.5 (𝑐𝑜𝑠30°)
∴ 𝒙𝟏 = 𝟏. 𝟐
For j = 2,
(2(2) − 1)𝜋
𝑥2 = 2.5 − 1.5 (𝑐𝑜𝑠 [ ])
6
3𝜋
∴ 𝑥2 = 2.5 − 1.5 (𝑐𝑜𝑠 [ ])
6
∴ 𝑥2 = 2.5 − 1.5 (𝑐𝑜𝑠90°)
∴ 𝒙𝟐 = 𝟐. 𝟓
For j = 3,
(2(3) − 1)𝜋
𝑥3 = 2.5 − 1.5 (𝑐𝑜𝑠 [ ])
6
5𝜋
∴ 𝑥3 = 2.5 − 1.5 (𝑐𝑜𝑠 [ ])
6
∴ 𝑥3 = 2.5 − 1.5 (𝑐𝑜𝑠150°)
∴ 𝒙𝟑 = 𝟑. 𝟖
Since y = x1.5, therefore the corresponding values of y are
𝒚𝑺 = (𝑥𝑆 )1.5 = (1)1.5 = 𝟏

𝒚𝟏 = (𝑥1 )1.5 = (1.2)1.5 = 𝟏. 𝟑𝟏𝟔
𝒚𝟐 = (𝑥2 )1.5 = (2.5)1.5 = 𝟑. 𝟗𝟓𝟐
𝒚𝟑 = (𝑥3 )1.5 = (3.8)1.5 = 𝟕. 𝟒𝟏
𝒚𝑭 = (𝑥𝐹 )1.5 = (4)1.5 = 𝟖
The three values of  corresponding to three precision points are given by
𝜃𝐹 − 𝜃𝑆
𝜃𝑗 = 𝜃𝑆 + (𝑥 − 𝑥𝑆 )
𝑥𝐹 − 𝑥𝑆 𝑗
120 − 30 90
∴ 𝜃𝑗 = 30 + (𝑥𝑗 − 1) = 30 + (𝑥𝑗 − 1) = 30 + 30(𝑥𝑗 − 1)
4−1 3
For j = 1,
∴ 𝜽𝟏 = 30 + 30(1.2 − 1) = 𝟑𝟔°
For j = 2,
∴ 𝜽𝟐 = 30 + 30(2.5 − 1) = 𝟕𝟓°
For j = 3,
∴ 𝜽𝟑 = 30 + 30(1.2 − 1) = 𝟏𝟏𝟒°
The three values of φ corresponding to three precision points are given by
𝜑 − 𝜑𝑆
𝜑𝑗 = 𝜑𝑆 + (𝑦 − 𝑦𝑆 )
𝑦𝐹 − 𝑦𝑆 𝑗
180 − 90 90
∴ 𝜑𝑗 = 90 + (𝑦𝑗 − 1) = 90 + (𝑦𝑗 − 1)
8−1 7
For j = 1,
90
∴ 𝝋𝟏 = 90 + (1.316 − 1) = 𝟗𝟒. 𝟎𝟔°
7
For j = 2,
90
∴ 𝝋𝟐 = 90 + (3.952 − 1) = 𝟏𝟐𝟕. 𝟗𝟓°
7
For j = 3,
90
∴ 𝝋𝟑 = 90 + (7.41 − 1) = 𝟏𝟕𝟐. 𝟒𝟏°
7
Ex. 2.2 [GTU; January-2017; 7 Marks] [GTU; December-2014; 7 Marks]
Design a four-bar mechanism to co-ordinate the input and output angles as follows:
Input angles = 15°, 30°, and 45°;
Output angles = 30°, 40°, and 55°.
1= 15; 2= 30; 3 = 45; φ1 = 30; φ2 = 40 and φ3 = 55

The Freudenstein’s equation is given by
𝑲𝟏 𝐜𝐨𝐬 𝝋 + 𝑲𝟐 𝐜𝐨𝐬 𝜽 + 𝑲𝟑 = 𝐜𝐨𝐬(𝜽 − 𝝋)

For 1= 15 and φ1 = 30;
𝐾1 cos 30 + 𝐾2 cos 15 + 𝐾3 = cos(15 − 30)

∴ 𝑲𝟏 (𝟎. 𝟖𝟔𝟔) + 𝑲𝟐 (𝟎. 𝟗𝟔𝟔) + 𝑲𝟑 = 𝟎. 𝟗𝟔𝟔 ⋯ ⋯ ⋯ (𝒊)
For 2= 30 and φ2 = 40;
𝐾1 cos 40 + 𝐾2 cos 30 + 𝐾3 = cos(30 − 40)

∴ 𝑲𝟏 (𝟎. 𝟕𝟔𝟔) + 𝑲𝟐 (𝟎. 𝟖𝟔𝟔) + 𝑲𝟑 = 𝟎. 𝟗𝟖𝟓 ⋯ ⋯ ⋯ (𝒊𝒊)
For 3= 45 and φ3 = 55;
𝐾1 cos 55 + 𝐾2 cos 45 + 𝐾3 = cos(45 − 55)

∴ 𝑲𝟏 (𝟎. 𝟓𝟕𝟒) + 𝑲𝟐 (𝟎. 𝟕𝟎𝟕) + 𝑲𝟑 = 𝟎. 𝟗𝟖𝟓 ⋯ ⋯ ⋯ (𝒊𝒊𝒊)
Solving the three simultaneous equations (i), (ii) and (iii), we get
k1 = 0.905 ; k2 = 1.01 and k3 = 1.158
Assuming the length of one of the links, say “a” as one unit, we get the length of the other
links.
Let us assume, a = 1 unit,
𝑑
𝐾1 =
𝑎
∴ 𝒅 = 𝑎 (𝐾1 ) = 1 (0.905) = 𝟎. 𝟗𝟎𝟓 𝒖𝒏𝒊𝒕𝒔
𝑑
𝐾2 =
𝑐
𝑑 0.905
∴𝒄= = = 𝟎. 𝟖𝟗𝟔 𝒖𝒏𝒊𝒕𝒔
𝐾2 1.01
𝑎2 − 𝑏2 + 𝑐 2 + 𝑑2
𝐾3 =
2𝑎𝑐
∴ 𝐾3 (2𝑎𝑐) = 𝑎2 − 𝑏 2 + 𝑐 2 + 𝑑 2
∴ 𝑏 2 = (𝑎2 + 𝑐 2 + 𝑑 2 ) − 𝐾3 (2𝑎𝑐)
∴ 𝒃 = 𝟎. 𝟕𝟒 𝒖𝒏𝒊𝒕𝒔

Ex. 2.3 Synthesize a 4 bar mechanism by the method of inversion for the following specifications.
𝑹𝑨𝑶𝟐 = 𝟐𝟎 𝐦𝐦 𝝍𝟏𝟐 = 𝟒𝟎° 𝝓𝟏𝟐 = 𝟑𝟎° 𝜽𝟐 = 𝟒𝟓°
𝑹𝑶𝟒 𝑶𝟐 = 𝟔𝟎 𝐦𝐦 𝝍𝟐𝟑 = 𝟑𝟓° 𝝓𝟐𝟑 = 𝟐𝟓°

Solution:
 The solution to the problem is given in the figure and is based on inverting the linkage
on link 4.
 First, we draw the input rocker O2A in the three specified positions and locate the
desired position for O4.
 Because we will invert on link 4 in the first design position we draw a ray from O 4 to
A2 and rotate it backward through the angle 𝜙12 to locate 𝐴′2 .
 Similarly, we draw another ray O4A3 and rotate it backward through the angle 𝜙13 to
locate 𝐴′3 .
 Because we are inverting on the first design position, A 1 and A′1 are coincident.
 Now we draw mid normals to the line A1 A′2 and A1 A′3 . These intersect at B1 and
define the length of coupler link 3 and the length of starting position of link 4.
Ex. 2.4 Four bar Crank-Rocker quick return linkage for specified time ratio. Time ratio = 1:1.25
with 45° output rocker motion. Design the synthesis.
Solution: 𝛼
𝑇𝑅 = 𝛼 + 𝛽 = 360°
𝛽
Construction angle 𝛿 = |180 − 𝛼|
= |180 − 𝛽|
1. Draw the output link O4B in both extreme positions, in any convenient location, such that
the desired angle of motion 𝜃4 , is subtended.
2. Calculate 𝛼, 𝛽, and 𝛿 using equations. In this example, 𝛼 = 160°, 𝛽 = 200°, 𝛿 = 20°.
3. Draw a construction line through point B1 at any convenient angle.
4. Draw a construction line through point B2 at angle 𝛿 from the first line.
5. Label the intersection of the two construction lines O 2.
6. The line O2O4 now defines the ground link.
7. Calculate the lengths of crank and coupler by measuring O 2B1 and O2B2 and solve
simultaneously.
Coupler + crank = 𝑂2 𝐵1
Coupler − crank = 𝑂2 𝐵2
Or we can construct the crank length by swinging an arc centered at O 2 from B1 to cut
line O2B2 extended. Label that intersection B1′ . The line B2 B1′ is twice the crank length.
Bisect this line segment to measure crank length O 2A1.
(a) (b)
(a) Construction of a quick return Grashof crank rocker
(b) The finished linkage in its two toggle positions
References:

Contents
3.1 Introduction ....................................................................................................................................... 3.2

3.2 The Motion of a Link ......................................................................................................................... 3.2
3.3 Velocities in Slider Crank Mechanism ............................................................................................. 3.3
3.4 The Velocity of a Point on a Link by Instantaneous Centre Method ............................................. 3.4
3.5 Properties of Instantaneous Centre ................................................................................................. 3.5
3.6 Kennedy’s Theorem .......................................................................................................................... 3.7
3.7 Acceleration Diagram for a Link ....................................................................................................... 3.8
3.8 Acceleration in Slider Crank Mechanism....................................................................................... 3.10
3.9 Problems .......................................................................................................................................... 3.11
3.1 Introduction
Linear Velocity: It may be defined as the rate of change of linear displacement of a body with respect to
the time. If the displacement is along a circular path, then the direction of linear velocity at any instant
is along the tangent at that point.
Linear Acceleration: It may be defined as the rate of change of linear velocity of a body with respect to
the time. The negative acceleration is also known as deceleration or retardation.
There are many methods for determining the velocity of any point on a link in a mechanism whose
direction of motion (i.e. path) and velocity of some other point on the same link is known in magnitude
and direction, yet the following two methods:
 Instantaneous centre method
 Relative velocity method

The instantaneous centre method is convenient and easy to apply in simple mechanisms, whereas the
relative velocity method may be used to any configuration diagram.
3.2 The Motion of a Link

Consider two points A and B on a rigid link AB, as shown in Fig.3.1 (a). Let one of the extremities (B) of the
link move relative to A, in a clockwise direction. Since the distance from A to B remains the same, therefore
there can be no relative motion between A and B, along the line AB. It is thus obvious, that the relative
motion of B with respect to A must be perpendicular to AB.
Hence velocity of any point on a link with respect to another point on the same link is always perpendicular
to the line joining these points on the configuration (or space) diagram.
The relative velocity of B with respect to A (i.e. VBA) is represented by the vector ab and is perpendicular
to the line AB as shown in Fig.3.1 (b).
Fig.3.1 - Motion of a Link

The velocity of point B with respect to A
𝒗𝑩𝑨 = 𝝎 × 𝑨𝑩 Eq. (3.1)
The velocity of point C on AB with respect to A
𝒗𝑪𝑨 = 𝝎 × 𝑨𝑪 Eq. (3.2)

Unit-3 Velocity and Acceleration Analysis
From Eq. (3.1) and Eq. (3.5),
𝒗𝑪𝑨 𝝎 × 𝑨𝑪 𝑨𝑪 Eq. (3.3)
= =
𝒗𝑩𝑨 𝝎 × 𝑨𝑩 𝑨𝑩
Thus, we see from Eq. (3.5), that the point c on the vector ab divides it in the same ratio as C divides the
link AB.
3.2.1 The Velocity of a Point on a Link by Relative Velocity Method
Fig.3.2 – Motion of points on a link and its velocity diagram

Consider two points A and B on a link AB. Let the absolute velocity of the point A i.e. VA is known in magnitude
and direction and the absolute velocity of the point B i.e. vB is known in direction only. Then the velocity of
B may be determined by drawing the velocity diagram as shown in Fig.3.2. The velocity diagram is drawn
as follows:
 Take some convenient point o, known as the pole.
 Through o, draw oa parallel and equal to VA, to some suitable scale.
 Through a, draw a line perpendicular to AB. This line will represent the velocity of B with respect to
A, i.e. VBA.
 Through o, draw a line parallel to v B intersecting the line of VBA at b.
 Measure ob, which gives the required velocity of point B (vB), to the scale.
3.3 Velocities in Slider Crank Mechanism
Fig.3.3 – Slider crank mechanism and its velocity diagram

A slider-crank mechanism is shown in Fig.3.3. The slider A is attached to the connecting rod AB. Let the
radius of crank OB be r and let it rotates in a clockwise direction, about the point O with uniform angular
velocity ω rad/s. Therefore, the velocity of B i.e. vB is known in magnitude and direction. The slider
reciprocates along the line of stroke AO.
The velocity of the slider A (i.e. VA) may be determined by the relative velocity method as discussed below:
 From any point o, draw vector ob parallel to the direction of vB (or perpendicular to OB) such that
ob = vB = ω.r, to some suitable scale.
 Since AB is a rigid link, therefore the velocity of A relative to B is perpendicular to AB. Now draw
vector ba perpendicular to AB to represent the velocity of A with respect to B i.e. v AB.
 From point o, draw vector oa parallel to the path of motion of the slider A (which is along AO only).
The vectors ba and oa intersect at a. Now oa represents the velocity of the slider I.e. VA, to the
scale.
The angular velocity of the connecting rod A B (ωAB) may be determined as follows:
𝒗𝑩𝑨 𝒂𝒃
𝝎𝑨𝑩 = =
𝑨𝑩 𝑨𝑩
3.3.1 Rubbing Velocity at a Pin Joint
Fig.3.4 - Links connected by pin joints

The links in a mechanism are mostly connected by means of pin joints. The rubbing velocity is defined as
the algebraic sum between the angular velocities of the two links which are connected by pin joints, multiplied
by the radius of the pin.
Consider two links OA and OB connected by a pin joint at O as shown in Fig.3.4.
Let,
ω1 = angular velocity of link OA
ω2 = angular velocity of link OB
According to the definition, rubbing velocity at the pin joint O,
= (𝜔1 − 𝜔1 ) × 𝑟 if the links move in the same direction
= (𝜔1 + 𝜔1 ) × 𝑟 if the links move in the same direction
3.4 The Velocity of a Point on a Link by Instantaneous Centre Method

The instantaneous centre method of analyzing the motion in a mechanism is based upon the concept that
any displacement of a body (or a rigid link) having motion in one plane, can be considered as a pure rotational
motion of a rigid link as a whole about some centre, known as instantaneous centre or virtual centre of
rotation.

Fig.3.5 - Velocity of a point on a link
The velocities of points A and B, whose directions are given a link by angles α and β as shown in Fig.3.5. If
vA is known in magnitude and direction and vB in direction only, then the magnitude of vB may be determined
by the instantaneous centre method as discussed below:
 Draw AI and BI perpendiculars to the directions VA and vB respectively. Let these lines intersect at
I, which is known as instantaneous centre or virtual centre of the link. The complete rigid link is to
rotate or turn about the centre I.
 Since A and B are the points on a rigid link, therefore there cannot be any relative motion between
them along line AB.
 Now resolving the velocities along AB,
𝑣𝐴 × 𝑐𝑜𝑠 𝛼 = 𝑣𝐵 × 𝑐𝑜𝑠 𝛽
𝑣𝐴 𝑐𝑜𝑠 𝛽 𝑠𝑖𝑛(90 − 𝛽) Eq. (3.4)
= =
𝑣𝐵 𝑐𝑜𝑠 𝛼 𝑠𝑖𝑛(90 − 𝛼)
 Applying Lami’s theorem to triangle ABI,
𝐴𝐼 𝐵𝐼
=
𝑠𝑖𝑛(90 − 𝛽) 𝑠𝑖𝑛(90 − 𝛼)
𝐴𝐼 𝑠𝑖𝑛(90 − 𝛽) Eq. (3.5)
 =
𝐵𝐼 𝑠𝑖𝑛(90 − 𝛼)
 From Eq. (3.4) and Eq. (3.5),
𝑣𝐴 𝐴𝐼
=
𝑣𝐵 𝐵𝐼
𝑣𝐴 𝑣𝐵
 = = 𝜔
𝐴𝐼 𝐵𝐼
 If C is any other point on a link, then
𝑣𝐴 𝑣𝐵 𝑣𝐶
= =
𝐴𝐼 𝐵𝐼 𝐶𝐼
3.5 Properties of Instantaneous Centre

The following properties of the instantaneous centre are important:
 A rigid link rotates instantaneously relative to another link at the instantaneous centre for the
configuration of the mechanism considered.

 The two rigid links have no linear velocity relative to each other at the instantaneous centre. At this
point (i.e. instantaneous centre), the two rigid links have the same linear velocity relative to the
third rigid link. In other words, the velocity of the instantaneous centre relative to any third rigid link
will be same whether the instantaneous centre is regarded as a point on the first rigid link or on the
second rigid link.
3.5.1 Number of Instantaneous Centre in a Mechanism

The number of instantaneous centres in a constrained kinematic chain is equal to the number of possible
combinations of two links. The number of pairs of links or the number of instantaneous centres is the
number of combinations of n links taken two at a time. Mathematically, number of instantaneous centres,
𝑛 (𝑛 − 1)
𝑁= , 𝑤ℎ𝑒𝑟𝑒 𝑛 = 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝐿𝑖𝑛𝑘
2
3.5.2 Types of Instantaneous Centres
Fig.3.6 - Types of instantaneous centres
The instantaneous centres for a mechanism are of the following three types:
1. Fixed instantaneous centres,
2. Permanent instantaneous centres, and
3. Neither fixed nor permanent instantaneous centres.
The first two types i.e. fixed and permanent instantaneous centres are together known as primary
instantaneous centres and the third type is known as secondary instantaneous centres.
Consider a four-bar mechanism ABCD as shown in Fig.3.6.
The instantaneous centres I12 and I14 are called the fixed instantaneous centres as they remain in the same
place for all configurations of the mechanism.
The instantaneous centres I23 and I34 are the permanent instantaneous centres as they move when the
mechanism moves, but the joints are of permanent nature.
The instantaneous centres I13 and I24 are neither fixed nor permanent instantaneous centres as they vary
with the configuration of the mechanism.

3.5.3 Location of Instantaneous Centres
Fig.3.7 - Location of instantaneous centres
The following rules may be used in locating the instantaneous centres in a mechanism:
1. When the two links are connected by a pin joint (or pivot joint), the instantaneous centre lies in the centre
of the pin as shown in Fig.3.7 (a). Such an instantaneous centre is of permanent nature, but if one of the
links is fixed, the instantaneous centre will be of fixed type.
2. When the two links have a pure rolling contact (i.e. link 2 rolls without slipping upon the fixed link 1
which may be straight or curved), the instantaneous centre lies on their point of contact, as shown in Fig.3.7
(b). The velocity of any point A on the link 2 relatives to fixed link 1 will be perpendicular to I12A and is
proportional to I12A.
3. When the two links have a sliding contact, the instantaneous centre lies on the common normal at the
point of contact. We shall consider the following three cases:
(a) When the link 2 (slider) moves on fixed link 1 having a straight surface as shown in Fig.3.7 (c),
the instantaneous centre lies at infinity and each point on the slider have the same velocity.
(b) When the link 2 (slider) moves on fixed link 1 having a curved surface as shown in Fig.3.7 (d),
the instantaneous centre lies on the centre of curvature of the curvilinear path in the configuration
at that instant.
(c) When the link 2 (slider) moves on fixed link 1 having a constant radius of curvature as shown
in Fig.3.7 (e), the instantaneous centre lies at the centre of curvature i.e. the centre of the circle, for
all configuration of the links.
3.6 Kennedy’s Theorem
Fig.3.8 - Aronhold Kennedy’s theorem

Aronhold Kennedy’s theorem states that “if three bodies move relative to each other, they have three
instantaneous centres and lie on a straight line.”
Consider three kinematic links A, B and C having relative plane motion. The number of instantaneous
centres (N) is given by
𝑛 (𝑛 − 1) 3 (3 − 1)
𝑁= = =3
2 2
The two instantaneous centres at the pin joints of B with A and C with A (i.e. Iab and Iac) are the permanent
instantaneous centre. According to Aronhold Kennedy’s theorem, the third instantaneous centre I bc must
lie on the line joining Iab and Iac.
In order to prove this, let us consider that the instantaneous centre I bc lies outside the line joining Iab and
Iac as shown in Fig.3.8. The point Ibc belongs to both the links B and C.
Let us consider the point Ibc on the link B. Its velocity vBC must be perpendicular to the line joining Iab and
Ibc. Now consider the point Ibc on the link C. Its velocity vBC must be perpendicular to the line joining Iac and
Ibc.
3.7 Acceleration Diagram for a Link
Fig.3.9 - Acceleration of a link

Consider two points A and B on a rigid link. Let the point B moves with respect to A, with an angular velocity
of ω rad/s and let α rad/s2 be the angular acceleration of the link AB.
We know that acceleration of a particle whose velocity changes both in magnitude and direction at any
instant has the following two components.
 The centripetal or radial component, which is perpendicular to the velocity of the particle at the
given instant.
 The tangential component, which is parallel to the velocity of the particle at the given instant.
Thus for a link A B, the velocity of point B with respect to A (i.e. VBA) is perpendicular to the link AB. Since
point B moves with respect to A with an angular velocity of ω rad/s, therefore a centripetal or radial
component of the acceleration of B with respect to A
𝒗𝟐𝑩𝑨⁄
𝒂𝒓𝑩𝑨 = 𝝎𝟐 × 𝑳𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝒍𝒊𝒏𝒌 𝑨𝑩 = 𝝎𝟐 × 𝑨𝑩 = 𝑨𝑩
This radial component of acceleration acts perpendicular to the velocity VBA. In other words, it acts parallel
to the link AB. The tangential component of the acceleration of B with respect to A,
𝒂𝒕𝑩𝑨 = 𝜶 × 𝑳𝒆𝒏𝒈𝒕𝒉 𝒐𝒇 𝒍𝒊𝒏𝒌 𝑨𝑩 = 𝜶 × 𝑨𝑩
This tangential component of acceleration acts parallel to the velocity VBA. In other words, it acts
perpendicular to the link AB.
In order to draw the acceleration diagram for a link AB, as shown in Fig.3.9, from any point b', draw vector
b'x parallel to BA to represent the radial component of acceleration of B with respect to A.
From point x, draw vector xa' perpendicular to BA to represent the tangential component of acceleration
of B with respect to A.
Join b'a'. The vector b'a' (known as acceleration image of the link AB) represents the total acceleration of
B with respect to A and it is the vector sum of radial component and the tangential component of
acceleration.
3.7.1 Acceleration of a Point on a Link

Consider two points A and B on the rigid link, as shown in Fig.3.10. Let the acceleration of the point A i.e.
aA is known in magnitude and direction and the direction of the path of B is given.
The acceleration of point B is determined in magnitude and direction by drawing the acceleration diagram
as discussed below:
 From any point o', draw vector o'a' parallel to the direction of absolute acceleration at point A i.e.
aA, to some suitable scale.
Fig.3.10 - Acceleration of a point on a link
 The acceleration of B with respect to A i.e. aBA has the following two components:
 The radial component of the acceleration of B with respect to A i.e. 𝒂𝒓𝑩𝑨
 The tangential component of the acceleration B with respect to A i.e. 𝒂𝒕𝑩𝑨
 Draw vector a’x parallel to the link AB such that,
𝑟 2 ⁄
𝑣𝑒𝑐𝑡𝑜𝑟 𝑎′ 𝑥 = 𝑎𝐵𝐴 = 𝑣𝐵𝐴 𝐴𝐵
 From point x, draw vector xb’ perpendicular to AB or vector a’x and through o’ draw a line parallel
to the path of B to represent the absolute acceleration of B i.e. a B.
 By joining the points a' and b' we may determine the total acceleration of B with respect to A i.e.
aBA. The vector a' b' is known as acceleration image of the link AB.
 For any other point C on the link, draw triangle a' b' c' similar to triangle ABC. Now vector b' c'
represents the acceleration of C with respect to B i.e. a CB, and vector a' c' represents the
acceleration of C with respect to A i.e. aCA. As discussed above, aCB and aCA will each have two
components as follows:
a. aCB has two components; 𝒂𝒓𝑪𝑩 and 𝒂𝒕𝑪𝑩 as shown by triangle b’zc’ in fig.b
b. aCA has two components; 𝒂𝒓𝑪𝑨 and 𝒂𝒕𝑪𝑨 as shown by triangle a’yc’
 The angular acceleration of the link AB is obtained by dividing the tangential component of
acceleration of B with respect to A to the length of the link.
𝑡 ⁄
𝛼𝐴𝐵 = 𝑎𝐵𝐴 𝐴𝐵
3.8 Acceleration in Slider Crank Mechanism
Fig.3.11 - Acceleration in the slider-crank mechanism and its acceleration diagram

A slider-crank mechanism is shown in Fig.3.11.
Let the crank OB makes an angle θ with the inner dead centre (I.D.C) and rotates in a clockwise direction
about the fixed point O with uniform angular velocity ωBO rad/s.
The velocity of B with respect to O or velocity of B (because O is a fixed point),
𝑣𝐵𝑂 = 𝑣𝐵 = 𝜔𝐵𝑂 × 𝑂𝐵 𝑎𝑐𝑡𝑖𝑛𝑔 𝑡𝑎𝑛𝑔𝑒𝑛𝑡𝑖𝑎𝑙𝑙𝑦 𝑎𝑡 𝐵
The centripetal or radial acceleration of B with respect to O or acceleration of B (Because O is a fixed
point),
2
𝑟 2
𝑣𝐵𝑂
𝑎𝐵𝑂 = 𝑎𝐵 = 𝜔𝐵𝑂 × 𝑂𝐵 =
𝐵𝑂
The acceleration diagram may be drawn as discussed below:
𝑟
a) Draw vector o' b' parallel to BO and set off equal in the magnitude of 𝑎𝐵𝑂 = 𝑎𝐵 , to some suitable
scale.
b) From point b', draw vector b'x parallel to BA. The vector b'x represents the radial component of the
acceleration of A with respect to B whose magnitude is given by:
𝑟 2 ⁄
𝑎𝐴𝐵 = 𝑣𝐴𝐵 𝐵𝐴
Since point B moves with constant angular velocity, therefore there will be no tangential component
of the acceleration.
c) From point x, draw vector xa’ perpendicular to b’x (or AB). The vector xa’ represents the tangential
components of the acceleration of A with respect to B.
d) Since point A reciprocates along AO, therefore the acceleration must be parallel to velocity.
Therefore from o', draw o' a' parallel to AO, intersecting the vector xa' at a'.
e) The vector b' a', which is the sum of the vectors b' x and x a', represents the total acceleration of A
with respect to B i.e. aAB. The vector b'a' represents the acceleration of the connecting rod AB.
f) The acceleration of any other point on A B such as E may be obtained by dividing the vector b' a' at
e' in the same ratio as E divides A B. In other words,
𝑎′𝑒′⁄𝑎′𝑏′ = 𝐴𝐸 ⁄𝐴𝐵
g) The angular acceleration of the connecting rod A B may be obtained by dividing the tangential
component of the acceleration of A with respect to B to the length of AB. In other words, the angular
acceleration of AB,
𝑡 ⁄
𝛼𝐴𝐵 = 𝑎𝐴𝐵 𝐴𝐵

3.9 Problems
Ex. 3.1 In a four-bar chain ABCD, AD is fixed and is 150 mm long. The crank AB is 40 mm long and
rotates at 120 r.p.m. clockwise, while the link CD = 80 mm oscillates about D. BC and AD are
of equal length. Find the angular velocity of link CD when angle BAD = 60°.
NBA = 120 r.p.m.
ωBA = 2 π × 120/60 = 12.568 rad/s
Since the length of crank AB = 40 mm = 0.04 m, therefore the velocity of B with respect to A or velocity
of B, (because A is a fixed point),
vBA = vB = ωBA × AB = 12.568 × 0.04 = 0.503 m/s
Since the link AD is fixed, therefore points a and d are taken as one point in the velocity diagram.
Draw vector ab perpendicular to BA, to some suitable scale, to represent the velocity of B with respect
to A or simply velocity of B (i.e. vBA or vB) such that
Vector ab = vBA = vB = 0.503 m/s
Now from point b, draw vector bc perpendicular to CB to represent the velocity of C with respect to B
(i.e. vCB) and from point d, draw vector dc perpendicular to CD to represent the velocity of C with respect
to D or simply velocity of C (i.e. vCD or vC). The vectors bc and dc intersect at c.
By measurement, we find that
VCD = vC = vector dc = 0.385 m/s
Angular velocity of link CD,
𝑣𝐶𝐷 0.385
𝜔𝐶𝐷 = = = 4.8 𝑟𝑎𝑑⁄𝑠
𝐶𝐷 0.08
Ex. 3.2 The crank and connecting rod of a theoretical steam engine are 0.5 m and 2 m long
respectively. The crank makes 180 r.p.m. in the clockwise direction. When it has turned
45° from the inner dead centre position, determine: 1. The velocity of the piston, 2. Angular
velocity of connecting rod, 3. The velocity of point E on the connecting rod 1.5 m from the
gudgeon pin, 4. velocities of rubbing at the pins of the crankshaft, crank and crosshead
when the diameters of their pins are 50 mm, 60 mm and 30 mm respectively, 5. Position and
linear velocity of any point G on the connecting rod which has the least velocity relative to
the crankshaft.
NBO = 180 r.p.m.
ωBO = 2 π × 180/60 = 18.852 rad/s

The extreme positions of the crank are shown in Figure.
Since the crank length OB = 0.5 m, therefore the linear velocity of B with respect to O or velocity of B
(because O is a fixed point),
vBO = vB = ωBO × OB = 18.852 × 0.5 = 9.426 m/s
First of all, draw the space diagram and then draw the velocity diagram as shown in the figure.
Draw vector ob perpendicular to BO, to some suitable scale, to represent the velocity of B with respect to
O or velocity of B such that
vector ob = vBO = vB = 9.426 m/s
From point b, draw vector bp perpendicular to BP to represent the velocity of P with respect to B (i.e. vPB)
and from point o, draw vector op parallel to PO to represent the velocity of P with respect to O (i.e. vPO or
simply vP). The vectors bp and op intersect at point p.
By measurement, we find that velocity of piston P,
𝒗𝑷 = 𝒗𝒆𝒄𝒕𝒐𝒓 𝒐𝒑 = 𝟖. 𝟏𝟓 𝒎/𝒔
From the velocity diagram, we find that the velocity of P with respect to B,
𝒗𝑷𝑩 = 𝒗𝒆𝒄𝒕𝒐𝒓 𝒃𝒑 = 𝟔. 𝟖 𝒎/𝒔
Since the length of connecting rod PB is 2 m, therefore the angular velocity of the connecting rod,
𝒗𝑷𝑩 𝟔. 𝟖
𝝎𝑷𝑩 = = = 𝟑. 𝟒 𝒓𝒂𝒅/𝒔
𝑷𝑩 𝟐
𝒗𝑬 = 𝒗𝒆𝒄𝒕𝒐𝒓 𝒐𝒆 = 𝟖. 𝟓 𝒎/𝒔
The velocity of rubbing at the pin of crank-shaft,
𝑑0
= × 𝜔𝐵𝑂 = 0.47 𝑚/𝑠
2
The velocity of rubbing at the pin of the crank,
𝑑𝐵
= (𝜔𝐵𝑂 + 𝜔𝑃𝐵 ) = 0.6675 𝑚/𝑠
2
The velocity of rubbing at the pin of the crank,
𝑑𝑐
= × 𝜔𝑃𝐵 = 0.051 𝑚/𝑠
2
By measurement, we find that,
𝑣𝑒𝑐𝑡𝑜𝑟 𝑏𝑔 = 5 𝑚/𝑠
By measurement, we find the linear velocity of point G,
𝑣𝐺 = 𝑣𝑒𝑐𝑡𝑜𝑟 𝑜𝑔 = 8 𝑚/𝑠

Ex. 3.3 The mechanism, as shown in the figure, has the dimensions of various links as
follows: AB = DE = 150 mm; BC = CD = 450 mm; EF = 375 mm. The crank AB makes an angle
of 45° with the horizontal and rotates about A in the clockwise direction at a uniform speed
of 120 r.p.m. The lever DC oscillates about the fixed point D, which is connected to AB by the
coupler BC. The block F moves in the horizontal guides, being driven by the link EF.
Determine: 1. velocity of the block F, 2. angular velocity of DC, and 3. rubbing speed at the pin
C which is 50 mm in diameter.
NBA = 120 RPM
ωBA = 2 π × 120/60 = 4 π rad/s
Since the crank length AB = 150 mm = 0.15 m, therefore velocity of B with respect to A or simply velocity
of B (because A is a fixed point),
vBA = vB = ωBA × AB = 4 π × 0.15 = 1.885 m/s
First of all, draw the space diagram, to some suitable scale, as shown in the figure. Now the velocity
diagram is drawn as discussed below:
Since the points A and D are fixed, therefore these points are marked as one point as shown in the
figure. Now from point a, draw vector ab perpendicular to A B, to some suitable scale, to represent the
velocity of B with respect to A or simply velocity of B, such that
Vector ab = vBA = vB = 1.885 m/s

The point C moves relative to B and D, therefore draw vector bc perpendicular to BC to represent the
velocity of C with respect to B (i.e. v CB), and from point d, draw vector dc perpendicular to DC to
represent the velocity of C with respect to D or simply velocity of C (i.e. v CD or vC). The vectors bc and
dc intersect at c.
Since the point E lies on DC, therefore divide vector dc in e in the same ratio as E divides CD. In other
words,
ce/cd = CE/CD
From point e, draw vector ef perpendicular to EF to represent the velocity of F with respect to E (i.e.
vFE) and from point d draw vector df parallel to the path of motion of F, which is horizontal, to represent
the velocity of F i.e. v F. The vectors ef and df intersect at f. By measurement, we find that velocity of
the block F,
vF = vector df = 0.7 m/s
By measurement from velocity diagram, we find that velocity of C with respect to D,
vCD = vector dc = 2.25 m/s
Since the length of link DC = 450 mm = 0.45 m, therefore the angular velocity of DC,
𝑣𝐶𝐷 𝑟𝑎𝑑
𝜔𝐷𝐶 = =5
𝐷𝐶 𝑠
From the velocity diagram, we find that velocity of C with respect to B,
vCB = vector bc = 2.25 m/s
Angular velocity of BC,
𝑣𝐶𝐷 2.25
𝜔𝐶𝐷 = = = 5 𝑟𝑎𝑑/𝑠
𝐵𝐶 0.45
Rubbing speed at the pin C,
= (CB – CD) rC
= (5 – 5) 0.025
=0
Ex. 3.4 The crank of the slider-crank mechanism rotates clockwise at a constant speed of 300
RPM. The crank is 150 mm and the connecting rod is 600 mm long. Determine:
1. Linear velocity and acceleration of the midpoint of the connecting rod, and
2. Angular velocity and angular acceleration of the connecting rod, at a crank
angle of 45° from the inner dead centre position
NBO = 300 r.p.m. or ωBO = 2 π × 300/60 = 31.42 rad/s;
OB = 150 mm = 0.15 m ; BA = 600 mm = 0.6 m
We know that linear velocity of B with respect to O or velocity of B,
𝑣𝐵𝑂 = 𝑣𝐵 = 𝜔𝐵𝑂 × 𝑂𝐵 = 31.42 × 0.15 = 4.713 𝑚/𝑠
Draw vector ob perpendicular to BO, to some suitable scale, to represent the velocity of B with respect
to O or simply velocity of B i.e. vBO or vB, such that
vector ob = vBO = vB = 4.713 m/s
From point b, draw vector ba perpendicular to BA to represent the velocity of A with respect to B i.e. v AB,
and from point o draw vector oa parallel to the motion of A (which is along AO) to represent the velocity
of A i.e. vA. The vectors ba and oa intersect at a.
By measurement, we find the velocity A with respect to B,
𝑣𝐴𝐵 = 𝑣𝑒𝑐𝑡𝑜𝑟 𝑏𝑎 = 3.4 𝑚/𝑠
𝑣𝐴 = vector oa = 4 m/s

In order to find the velocity of the midpoint D of the connecting rod A B, divide the vector ba at d in the
same ratio as D divides A B, in the space diagram. In other words,
𝑏𝑑⁄𝑏𝑎 = 𝐵𝐷⁄𝐵𝐴
vD = vector od = 4.1 m/s
We know that the radial component of the acceleration of B with respect to O or the acceleration of B,
2
2
𝑣𝐵𝑂 (4.713)2
𝑎𝐵𝑂 = 𝑎𝐵 = = = 148.1 𝑚/𝑠 2
𝑂𝐵 0.15
And the radial component of the acceleration of A with respect to B,
2
𝑟
𝑣𝐴𝐵 (3.4)2
𝑎𝐴𝐵 = = = 19.3 𝑚/𝑠 2
𝐵𝐴 0.6
𝑟
𝑣𝑒𝑐𝑡𝑜𝑟 𝑜 ′ 𝑏 ′ = 𝑎𝐵𝑂 = 𝑎𝐵 = 148.1 𝑚/𝑠 2
𝑎𝐷 = 𝑣𝑒𝑐𝑡𝑜𝑟 𝑜 ′ 𝑑′ = 117 𝑚/𝑠 2
We know that angular velocity of the connecting rod AB,
𝑣𝐴𝐵 3.4
𝜔𝐴𝐵 = = = 5.67 𝑟𝑎𝑑⁄𝑠 2
𝐵𝐴 0.6
From the acceleration diagram, we find that
atAB = 103 m⁄s 2
We know that angular acceleration of the connecting rod AB,
𝑡
𝑎𝐴𝐵 103
𝛼𝐴𝐵 = = = 171.67 𝑟𝑎𝑑 ⁄𝑠 2
𝐵𝐴 0.6
Ex. 3.5 An engine mechanism is shown in the figure. The crank CB = 100 mm and the connecting
rod BA = 300 mm with the centre of gravity G, 100 mm from B. In the position shown, the
crankshaft has a speed of 75 rad/s and angular acceleration of 1200 rad/s 2. Find:
1. The velocity of G and angular velocity of AB, and
2. Acceleration of G and angular acceleration of AB.
ωBC = 75 rad/s ; αBC = 1200 rad/s2, CB = 100 mm = 0.1 m; B A = 300 mm = 0.3 m
We know that velocity of B with respect to C or velocity of B
vBC = vB = ωBC × CB = 75 × 0.1 = 7.5 m/s

Since the angular acceleration of the crankshaft, αBC = 1200 rad/s2, therefore tangential component of
the acceleration of B with respect to C,
𝑡
𝑎𝐵𝐶 = 𝛼𝐵𝐶 × 𝐶𝐵 = 1200 × 0.1 = 120 𝑚⁄𝑠 2
𝑚
𝑣𝑒𝑐𝑡𝑜𝑟 𝑐𝑏 = 𝑣𝐵𝐶 = 𝑣𝐵 = 7.5
𝑠
By measurement, we find that velocity of G,

𝑣𝐺 = 𝑣𝑒𝑐𝑡𝑜𝑟 𝑐𝑔 = 6.8 𝑚/𝑠
From the velocity diagram, we find that the velocity of A with respect to B,
𝑣𝐴𝐵 = 𝑣𝑒𝑐𝑡𝑜𝑟 𝑏𝑎 = 4 𝑚/𝑠
We know that angular velocity of AB,
𝑣𝐴𝐵 4
𝜔𝐴𝐵 = = = 13.3 𝑟𝑎𝑑/𝑠
𝐵𝐴 0.3
We know that radial component of the acceleration of B with respect to C

2
𝑟
𝑣𝐵𝐶 (7.5)2
𝑎𝐵𝐶 = = = 562.5 𝑚⁄𝑠 2
𝐶𝐵 0.1
And a radial component of the acceleration of A with respect to B,
𝑟
𝑣𝐴2 (4)2
𝑎𝐴𝐵 = = = 53.3 𝑚⁄𝑠 2
𝐶𝐵 0.3
𝑟
𝑣𝑒𝑐𝑡𝑜𝑟 𝑐 ′ 𝑏 ′′ = 𝑎𝐵𝐶 = 562.5 𝑚/𝑠 2
𝑡
𝑣𝑒𝑐𝑡𝑜𝑟 𝑏 ′′ 𝑏 ′ = 𝑎𝐵𝐶 = 120 𝑚/𝑠 2
𝑟
𝑣𝑒𝑐𝑡𝑜𝑟 𝑏 ′ 𝑥 = 𝑎𝐴𝐵 = 53.3 𝑚/𝑠 2
By measurement, we find that acceleration of G,
𝑎𝐺 = 𝑣𝑒𝑐𝑡𝑜𝑟 𝑥𝑎′ = 414 𝑚/𝑠 2

From the acceleration diagram, we find that tangential component of the acceleration of A with respect
to B,
𝑡
𝑎𝐴𝐵 = 𝑣𝑒𝑐𝑡𝑜𝑟 𝑥𝑎′ = 546 𝑚/𝑠 2
Angular acceleration of AB,
𝑡
𝑎𝐴𝐵 546
𝛼𝐴𝐵 = = = 1820 𝑟𝑎𝑑/𝑠 2
𝐵𝐴 0.3
References:

Contents
4.1 Introduction to Cam and Follower ................................................................................................... 4.2

4.2 Classification of Followers ............................................................................................................... 4.2
4.3 Classification of Cams...................................................................................................................... 4.5
4.4 Terminology in Cams ........................................................................................................................ 4.6
4.5 Motions of the Follower .................................................................................................................... 4.7
4.6 Problems .......................................................................................................................................... 4.14
4.1 Introduction to Cam and Follower
A cam is a rotating machine element which gives reciprocating or oscillating motion to another element
known as a follower.
 The cam and the follower have a line contact and constitute a higher pair.
 The cams are usually rotated at a uniform speed by a shaft, but the follower motion is
predetermined and will be according to the shape of the cam.
 Applications: The cams are widely used for operating the inlet and exhaust valves of internal
combustion engines, automatic attachment of machinery, paper cutting machines, spinning and
weaving textile machinery, feed mechanism of automatic lathes etc.
4.2 Classification of Followers

The followers may be classified as discussed below:
4.2.1 According to the surface in contact

According to the surface in contact, the followers may be classified as follow:
4.2.1.1 Knife edge follower

When the contacting end of the follower has a sharp knife-edge, it is called a knife-edge follower.
 The sliding motion takes place between the contacting surfaces (i.e. the knife edge and the cam
surface).
 It is now used widely in practice because of the small area of contacting surface results in
excessive wear.
 In knife-edge followers, a considerable side thrust exists between the follower and the guide.
Fig.4.1 - Cam with knife-edge follower
4.2.1.2 Roller follower

When the contacting end of the follower is a roller, it is called a roller follower.
 Rolling motion takes place between the contacting surfaces (i.e. the roller and the cam), therefore
the rate of wear is greatly reduced.
 In roller followers also the side thrust exists between the follower and the guide.

4.2
Kinematics and Theory of Machines (3131906) | Unit-4 Cams
 The roller followers are extensively used where more space is available such as in stationary gas
and oil engines and aircraft engines.
Fig.4.2 - Cam with roller follower
4.2.1.3 Flat-faced or mushroom follower

When the contacting end of the follower is a perfectly flat face, it is called a flat-faced follower.
 It may be noted that the side thrust between the follower and the guide is much reduced in the case
of flat-faced followers.
 The flat-faced followers are generally used where space is limited such as in cams which operate
the valves of automobile engines.
 When the flat-faced follower is circular, it is then called a mushroom follower.
Fig.4.3 – Cam with flat-faced follower
4.2.1.4 Spherical faced follower

When the contacting end of the follower is of spherical shape, it is called a spherical faced follower.
 It may be noted that when a flat-faced follower is used in automobile engines, high surface stresses
are produced.
 In order to minimise these stresses, the flat end of the follower is machined to a spherical shape.

4.3
Fig.4.4 - Cam with spherical faced follower
4.2.2 According to the motion of the follower

The followers, according to its motion, are of the following two types:
4.2.2.1 Reciprocating or translating follower

When the follower reciprocates in guides as the cam rotates uniformly, it is known as a reciprocating or
translating follower.
Fig.4.5 - Reciprocating or translating followers
4.2.2.2 Oscillating or rotating follower

When the uniform rotary motion of the cam is converted into predetermined oscillatory motion of the
follower, it is called oscillating or rotating follower.
Fig.4.6 – Oscillating follower

4.4
4.2.3 According to the path of motion of the follower
The followers, according to its path of motion, are of the following two types:
4.2.3.1 Radial follower

When the motion of the follower is along an axis passing through the centre of the cam, it is known as a
radial follower.
4.2.3.2 Off-set follower

When the motion of the follower is along an axis away from the axis of the cam centre, it is called off-set
follower.
Fig.4.7 - Cam with offset follower
4.3 Classification of Cams

Though the cams may be classified in many ways, yet the following two types are important:
4.3.1 Radial or disc cam

In radial cams, the follower reciprocates or oscillates in a direction perpendicular to the cam axis. The
cams as shown in Fig.4.5 are all radial cams.
4.3.2 Cylindrical cam

In cylindrical cams, the follower reciprocates or oscillates in a direction parallel to the cam axis. The
follower rides in a groove at its cylindrical surface. A cylindrical grooved cam with a reciprocating and an
oscillating follower is shown in Fig.4.8 respectively.
Fig.4.8 - (a) Cylindrical cam with a reciprocating follower (b) Cylindrical cam with oscillating follower

4.5
4.4 Terminology in Cams
Fig.4.9 - Terms used in radial cams
1. Base circle: It is the smallest circle that can be drawn to the cam profile.
2. Trace point: It is a reference point on the follower and is used to generate the pitch curve.
 In the case of knife-edge follower, the knife-edge represents the trace point and the pitch curve
corresponds to the cam profile.
 In a roller follower, the centre of the roller represents the trace point.
3. Pressure angle: It is the angle between the direction of the follower motion and a normal to the
pitch curve
 This angle is very important in designing a cam profile. If the pressure angle is too large, a
reciprocating follower will jam in its bearings.
4. Pitch point: It is a point on the pitch curve having the maximum pressure angle.
5. Pitch circle: It is a circle drawn from the centre of the cam through the pitch points.
6. Pitch curve: It is the curve generated by the trace point as the follower moves relative to the cam.
 For a knife-edge follower, the pitch curve and the cam profile are the same whereas, for a roller
follower, they are separated by the radius of the roller.
7. Prime Circle: It is the smallest circle that can be drawn from the centre of the cam and tangent to
the pitch curve.
 For a knife-edge and a flat face follower, the prime circle and the base circle are identical.
 For a roller follower, the prime circle is larger than the base circle by the radius of the roller.
8. Lift or stroke: It is the maximum travel of the follower from its lowest position to the topmost
position.

4.6
4.5 Motions of the Follower
During its travel, the follower may have one of the following motions:
a) Uniform velocity
b) Simple harmonic motion
c) Uniform acceleration and retardation
d) Cycloidal motion
4.5.1 Displacement, Velocity and Acceleration Diagrams when the Follower Moves with
Uniform Velocity
Fig.4.10 - Displacement, velocity and acceleration diagrams when the follower moves with uniform velocity
 The displacement, velocity and acceleration diagrams when a knife-edged follower moves with
uniform velocity are shown in Fig.4.10.
 The abscissa (base) represents the time (i.e. the number of seconds required for the cam to
complete one revolution) or it may represent the angular displacement of the cam in degrees. The
ordinate represents the displacement or velocity or acceleration of the follower.
 Since the follower moves with uniform velocity during its rise and return stroke, therefore the slope
of the displacement curves must be constant. In other words, AB1 and C1D must be straight lines.

4.7
 A little consideration will show that the follower remains at rest during part of the cam rotation.
The periods during which the follower remains at rest are known as dwell periods, as shown by
lines B1C1 and DE.
 The acceleration or retardation of the follower at the beginning and at the end of each stroke is
infinite. This is due to the fact that the follower is required to start from rest and has to gain a
velocity within no time.
 This is only possible if the acceleration or retardation at the beginning and at the end of each stroke
is infinite. These conditions are, however, impracticable.
4.5.2 Displacement, Velocity and Acceleration Diagrams when the Follower Moves with Simple
Harmonic Motion (S.H.M.)
Fig.4.11 - Displacement, velocity & acceleration diagrams when follower moves with simple harmonic motion
 The displacement, velocity and acceleration diagrams when the follower moves with simple
harmonic motion are shown in Fig.4.11. The displacement diagram is drawn as follows:
1. Draw a semi-circle on the follower stroke as diameter.
2. Divide the semi-circle into any number of even equal parts.
3. Divide the angular displacements of the cam during outstroke and return stroke into the
same number of equal parts.
4. The displacement diagram is obtained by projecting the points.
 Since the follower moves with a simple harmonic motion, therefore velocity diagram consists of a
sine curve and the acceleration diagram is a cosine curve.

4.8
 The velocity of the follower is zero at the beginning and at the end of its stroke and increases
gradually to a maximum at mid-stroke.
 On the other hand, the acceleration of the follower is maximum at the beginning and at the ends
of the stroke and diminishes to zero at mid-stroke.
 Let,
S = Stroke of the follower

o and R = Angular displacement of the cam during out stroke and return stroke of the follower
respectively
ω = Angular velocity of cam
The time required for the outstroke of the follower in second
𝜃0
𝑡0 =
𝜔
 Consider a point P moving at uniform speed ωp radians per second around the circumference of a
circle with the stroke S as diameter. The point (which is the projection of a point P on the diameter)
executes a simple harmonic motion as the point P rotates. The motion of the follower is similar to
that of point P’.
Fig.4.12 - Motion of a point
 The peripheral speed of the point P’
𝜋 ×𝑠 1 𝜋 ×𝑠 𝜔
𝑣𝑝 = × = ×
2 𝑡0 2 𝜃0
 Maximum velocity of the follower on the outstroke,
𝜋 ×𝑠 𝜔 𝜋 × 𝜔 ×𝑠
𝑣0 = 𝑣𝑝 = × =
2 𝜃0 2 𝜃0
 We know that the centripetal acceleration of the point P
𝑣𝑝 2 𝜋 × 𝜔 ×𝑠 2 2 𝜋 2 × 𝜔2 × 𝑠
𝑎𝑝 = = ( ) × =
𝑜𝑝 2 𝜃0 𝑠 2 × (𝜃0 )2
 Maximum acceleration of the follower on the outstroke,
𝜋 2 × 𝜔2 × 𝑠
𝑎0 = 𝑎𝑝 =
2 × (𝜃0 )2

4.9
 Similarly, the maximum velocity of the follower on the return stroke,
𝜋× 𝜔 ×𝑆
𝑣𝑅 =
2 𝜃𝑅
 Maximum acceleration of the follower on the return stroke
𝜋 2 𝜔2 𝑆
𝑎𝑅 =
2 (𝜃𝑅 )2
Uniform Acceleration and Retardation
Fig.4.13 - Displacement, velocity and acceleration diagrams when the follower moves with uniform
acceleration and retardation
 The displacement, velocity and acceleration diagrams when the follower moves with uniform
acceleration and retardation are shown in Fig.4.13.

4.10
 The displacement diagram consists of a parabolic curve and may be drawn as discussed below:
1. Divide the angular displacement of the cam during outstroke (O) into an even number of
equal parts (say eight) and draw vertical lines through these points.
2. Divide the stroke of the follower (S) into the same number of equal even parts.
3. Join Aa to intersect the vertical line through point 1 at B. Similarly, obtain the other points
C, D etc. Now join these points to obtain the parabolic curve for the outstroke of the
follower.
4. In a similar way, the displacement diagram for the follower during return stroke may be
drawn.
 Since the acceleration and retardation is uniform, therefore the velocity varies directly with the
time.
 We know that time required for the follower during outstroke,
𝜃0
𝑡0 =
𝜔
 The time required for the follower during the return stroke,
𝜃𝑅
𝑡𝑅 =
𝜔
 Mean velocity of the follower during outstroke
𝑆
𝑣0 =
𝑡0
 Since the maximum velocity of the follower is equal to twice the mean velocity, therefore the
maximum velocity of the follower during outstroke,
2𝑆 2𝜔𝑆
𝑣0 = =
𝑡0 𝜃0
 Similarly, the maximum velocity of the follower during the return stroke,
2𝜔𝑆
𝑣𝑅 =
𝜃𝑅
 Maximum acceleration of the follower during outstroke,
𝑣0 2 ×2𝜔𝑠 4 𝜔2 . 𝑆
𝑎0 = = =
𝑡0 ⁄2 𝑡0 𝜃0 (𝜃0 )2
 Similarly, the maximum acceleration of the follower during the return stroke,
4 𝜔2 𝑆
𝑎𝑅 =
(𝜃𝑅 )2
Cycloidal Motion
 The displacement, velocity and acceleration diagrams when the follower moves with cycloidal
motion are shown in Fig.4.14.
 We know that cycloid is a curve traced by a point on a circle when the circle rolls without slipping
on a straight line.

4.11
 In the case of cams, this straight line is a stroke of the follower which is translating and the
circumference of the rolling circle is equal to the stroke (S) of the follower. Therefore the radius of
𝑺
the rolling circle is .
𝟐𝝅
Fig.4.14 - Displacement, velocity and acceleration diagrams when the follower moves with the cycloidal
motion
 The displacement diagram can be drawn as discussed below:

𝑺
1. Draw a circle of radius 𝟐 𝝅 A as a centre.
2. Divide the circle into any number of six even parts. Project these points horizontally on the
vertical centre line of the circle. These points are shown by a’ and b’.
3. Divide the angular displacement of the cam during outstroke into the same number of equal
even parts as the circle is divided. Draw vertical lines through these points.
4. Join AB which intersects the vertical line through 3’ at c. From a’ draw a line parallel to AB
intersecting the vertical lines through 1’ and 2’ at a and b respectively.
5. Similarly, from b’ draw a line parallel to AB intersecting the vertical lines through 4’ and 5’
at d and e respectively.
6. Join the points A a b c d e B by a smooth curve. This is the required cycloidal curve for the
follower during outstroke.

4.12
 We know that displacement of the follower after time t seconds,
𝜃 1 2𝜋𝜃
𝑥=𝑆 [ − sin ( )]
𝜃0 2 𝜋 𝜃0
 The velocity of the follower after time t seconds,
𝑑𝑥 1 𝑑𝜃 2 𝜋 𝜃 2 𝜋 𝜃 𝑑𝜃
=𝑆 [ × − cos ( ) ]
𝑑𝑡 𝜃0 𝑑𝑡 𝜃0 𝜃0 𝑑𝑡
𝑆 𝑑𝜃 2𝜋𝜃
= × [1 − cos ( )]
𝜃0 𝑑𝑡 𝜃0
𝜔𝑆 2𝜋𝜃
= [1 − cos ( )]
𝜃0 𝜃0
 The velocity is maximum, when
2𝜋𝜃
cos ( ) = −1
𝜃0
2𝜋𝜃
= 𝜋
𝜃0
𝜃0
𝜃=
2
 Similarly, the maximum velocity of the follower during the return stroke,
2𝜔𝑆
𝑣𝑅 =
𝜃𝑅
 Now, acceleration of the follower after time t sec,
𝑑2𝑥 𝜔𝑆 2𝜋 2 𝜋 𝜃 𝑑𝜃
= [ sin ( ) ]
𝑑𝑡 2 𝜃0 𝜃0 𝜃0 𝑑𝑡
2 𝜋 𝜔2 𝑆 2𝜋𝜃
= 2
sin ( )
(𝜃0 ) 𝜃0
 The acceleration is maximum, when
2𝜋𝜃
sin ( )=1
𝜃0
𝜃0
𝜃=
4
2 𝜋 𝜔2 𝑆
𝑎0 =
(𝜃0 )2
2 𝜋 𝜔2 𝑆
𝑎𝑅 =
(𝜃𝑅 )2

4.13
4.6 Problems
Ex. 4.1 A cam is to give the following motion to a knife-edged follower:
1. Outstroke during 60° of cam rotation;
2. Dwell for the next 30° of cam rotation;
3. Return stroke during next 60° of cam rotation, and
4. Dwell for the remaining 210° of cam rotation.
The stroke of the follower is 40 mm and the minimum radius of the cam is 50 mm. The
follower moves with uniform velocity during both the outstroke and return strokes. Draw
the profile of the cam when (a) the axis of the follower passes through the axis of the
camshaft, and (b) the axis of the follower is offset by 20 mm from the axis of the camshaft.
S = 40 mm; Minimum Radius of the Cam = 50 mm
Fig.4.15 - Displacement diagram
Fig.4.16 - Profile of the cam when the line of stroke of the follower passes through the axis of the camshaft

4.14
Fig.4.17 - The profile of the cam when the axis of the follower is offset from the axis of the camshaft
Ex. 4.2 A cam is to be designed for a knife-edge follower with the following data:
1. Cam lift = 40 mm during 90° of cam rotation with simple harmonic motion.
2. Dwell for the next 30°.
3. During the next 60° of cam rotation, the follower returns to its original position with SHM.
4. Dwell during the remaining 180°.
Draw the profile of the cam when
(a) the line of stroke of the follower passes through the axis of the camshaft, and
(b) the line of stroke is offset 20 mm from the axis of the camshaft.
The radius of the base circle of the cam is 40 mm. Determine the maximum velocity and
acceleration of the follower during its ascent and descent, if the cam rotates at 240 r.p.m.
S = 40 mm = 0.04 m; Minimum Radius of the Cam = 40 mm; o = 90° = /2 rad = 1.571 rad;
R = 60° =/3 rad = 1.047 rad; N = 240 r.p.m.

4.15
Fig.4.19 - Profile of the cam when the line of stroke of the follower passes through the axis of the camshaft
Fig.4.20 - The profile of the cam when the axis of the follower is offset from the axis of the camshaft
 Angular velocity of the cam,
2𝜋𝑁 2 𝜋 (240)
𝜔= = = 25.14 𝑟𝑎𝑑/𝑠
60 60
𝜋 × 𝜔 ×𝑠 𝜋 × 25.14 × 0.04
𝑣0 = = = 1 𝑚/𝑠
2 𝜃0 2 × 1.571
 Maximum velocity of the follower on the return stroke,
𝜋 × 𝜔 ×𝑠 𝜋 × 25.14 × 0.04
𝑣𝑅 = = = 1.51 𝑚/𝑠
2 𝜃𝑅 2 × 1.047

4.16
𝜋 2 × 𝜔2 × 𝑠 𝜋 2 × (25.14)2 × 0.04
𝑎0 = = = 50.6 𝑚/𝑠 2
2 × (𝜃0 )2 2 × (1.571)2
 Maximum acceleration of the follower on the return stroke,
𝜋 2 × 𝜔2 × 𝑠 𝜋 2 × (25.14)2 × 0.04
𝑎𝑅 = = = 113.8 𝑚/𝑠 2
2 × (𝜃𝑅 )2 2 × (1.047)2
Ex. 4.3 A cam drives a flat reciprocating follower in the following manner:
During the first 120° rotation of the cam, the follower moves outwards through a distance
of 20 mm with simple harmonic motion. The follower dwells during next 30° of cam
rotation. During the next 120° of cam rotation, the follower moves inwards with simple
harmonic motion. The follower dwells for the next 90° of cam rotation. The minimum
radius of the cam is 25 mm. Draw the profile of the cam.
S = 20 mm; Minimum Radius of the Cam = 25 mm
Fig.4.22 - The profile of the cam driving a flat reciprocating follower

4.17
Ex. 4.4 A cam, with a minimum radius of 50 mm, rotating clockwise at a uniform speed, is required
to give a knife-edge follower the motion as described below:
1. To move outwards through 40 mm during 100° rotation of the cam;
2. To dwell for the next 80°;
3. To return to its starting position during the next 90°, and
4. To dwell for the rest period of a revolution i.e. 90°.
Draw the profile of the cam
(i) when the line of stroke of the follower passes through the centre of the camshaft, and
(ii) when the line of stroke of the follower is off-set by 15 mm.
The displacement of the follower is to take place with uniform acceleration and uniform
retardation. Determine the maximum velocity and acceleration of the follower when the
camshaft rotates at 900 r.p.m. Draw the displacement, velocity and acceleration diagrams
for one complete revolution of the cam.
S = 40 mm = 0.04 m; Minimum Radius of the Cam = 50 mm;
o = 100° = 100 (/180) rad = 1.745 rad; R = 90° =/2 rad = 1.571 rad; N = 900 r.p.m.
Fig.4.23 – Displacement, velocity and acceleration diagram

4.18
Fig.4.24 - Profile of the cam when the line of stroke of follower passes through the centre of the camshaft
Fig.4.25 - Profile of the cam when the line of stroke of the follower is offset by 15 mm

4.19
2𝜋𝑁 2 𝜋 (900)
𝜔= = = 94.26 𝑟𝑎𝑑/𝑠
60 60
2 × 𝜔 ×𝑠 2 × 94.26 × 0.04
𝑣0 = = = 4.32 𝑚/𝑠
𝜃0 1.745
2 × 𝜔 ×𝑠 2 × 94.26 × 0.04
𝑣𝑅 = = = 4.8 𝑚/𝑠
𝜃𝑅 1.571
4 × 𝜔2 × 𝑠 4 × (94.26)2 × 0.04
𝑎0 = = = 467 𝑚/𝑠 2
(𝜃0 )2 (1.745)2
4 × 𝜔2 × 𝑠 4 × (94.26)2 × 0.04
𝑎𝑅 = = = 576 𝑚/𝑠 2
(𝜃𝑅 )2 (1.571)2
Ex. 4.5 A cam rotating clockwise at a uniform speed of 1000 r.p.m. is required to give a roller
follower the motion as defined below:
1. A follower to move outwards through 50 mm during 120° of cam rotation,
2. A follower to dwell for next 60° of cam rotation,
3. A follower to return to its starting position during next 90° of cam rotation,
4. A follower to dwell for the rest of the cam rotation.
The minimum radius of the cam is 50 mm and the diameter of the roller is 10 mm. The line
of stroke of the follower is off-set by 20 mm from the axis of the camshaft. If the
displacement of the follower takes place with uniform and equal acceleration and
retardation on both the outward and return strokes, draw the profile of the cam and find
the maximum velocity and acceleration during out stroke and return stroke.
o = 120° = 120 (/180) rad = 2.1 rad; R = 90° =/2 rad = 1.571 rad; N = 1000 r.p.m.
Fig.4.26 – Displacement diagram

4.20
Fig.4.27 - Profile of the cam when the line of stroke of the follower is offset by 20 mm
2𝜋𝑁 2 𝜋 (1000)
𝜔= = = 104.7 𝑟𝑎𝑑/𝑠
60 60
2 × 𝜔 ×𝑠 2 × 104.7 × 0.05
𝑣0 = = = 5 𝑚/𝑠
𝜃0 2.1
2 × 𝜔 ×𝑠 2 × 104.7 × 0.05
𝑣𝑅 = = = 6.66 𝑚/𝑠
𝜃𝑅 1.571
4 × 𝜔2 × 𝑠 4 × (104.7)2 × 0.05
𝑎0 = = = 497.2 𝑚/𝑠 2
(𝜃0 )2 (2.1)2
4 × 𝜔2 × 𝑠 4 × (104.7)2 × 0.05
𝑎𝑅 = = = 888 𝑚/𝑠 2
(𝜃𝑅 )2 (1.571)2
Ex. 4.6 Construct the profile of a cam to suit the following specifications:
Camshaft diameter = 40 mm ; Least radius of cam = 25 mm ; Diameter of roller = 25 mm;
The angle of lift = 120°; Angle of fall = 150°; Lift of the follower = 40 mm; Number of pauses
are two of the equal interval between motions. During the lift, the motion is S.H.M. During
the fall the motion is uniform acceleration and deceleration. The speed of the camshaft is
uniform. The line of stroke of the follower is offset 12.5 mm from the centre of the cam.

4.21
Fig.4.28 – Displacement diagram
Fig.4.29 - Profile of the cam when the line of stroke of the follower is offset by 12.5 mm
References:

4.22
Contents
5.1 Introduction ....................................................................................................................................... 5.2

5.2 Selection of Belt drive ....................................................................................................................... 5.2
5.3 Types of Belt drives ........................................................................................................................... 5.2
5.4 Law of Belting .................................................................................................................................... 5.7
5.5 Slip of Belt .......................................................................................................................................... 5.8
5.6 Creep of Belt ...................................................................................................................................... 5.8
5.7 Length of an Open Belt Drive ............................................................................................................ 5.9
5.8 Length of Crossed Belt Drive .......................................................................................................... 5.10
5.9 Ratio of Friction Tensions............................................................................................................... 5.12
5.10 Power Transmitted by a belt .......................................................................................................... 5.15
5.11 Angle of Contact or Angle of Lap ................................................................................................... 5.15
5.12 Centrifugal effect on Belt ................................................................................................................ 5.16
5.13 Maximum Power transmitted by a belt ......................................................................................... 5.18
5.14 Initial Tension in the Belt ................................................................................................................ 5.19
5.15 Crowning of Pulley .......................................................................................................................... 5.20
5.16 Advantages & Disadvantages of V – Belt drive over Flat Belt drive ............................................ 5.21
5.17 Rope drive ........................................................................................................................................ 5.21
5.18 Chain Drive ....................................................................................................................................... 5.23
5.19 Problems .......................................................................................................................................... 5.27
5.1 Introduction
Power is transmitted from one shaft to another by means of Belt, rope, chain and gears.
Salient Features:
 Belt, rope and chain are used where the distance between the shaft is large. For small distance,
gears are preferred.
 Belt, rope and chain are the flexible types of connectors, i.e., they are bent easily.
 The flexibility of belt and rope is due to the property of their materials whereas chains have a
number of small rigid elements having relative motion between the two elements.
 Belt and rope transmit power due to friction between them and the pulley. If the power transmitted
exceeds the force of friction, the belt or rope slips over the pulley.
 Belts and ropes are strained during motion as tensions are developed in them.
 Owing to slipping and straining action belts and ropes are not positive drive, i.e., velocity ratio are
not constant. Chain and gears have a constant velocity ratio.
5.2 Selection of Belt drive

Following are the factors which affect the selection of belt drive:
 Speed of driving and driven shafts.
 Power to be transmitted.
 Space available.
 Service conditions.
 Centre distance between the shafts.
 Speed reduction ratio.
5.3 Types of Belt drives

a) Light drives
 Small power.
 V ≤ 10 m/s Agricultural machine, Small machine.

b) Medium drives
 Medium power
 22 < V > 10 m/s, Machine tool.

c) Heavy drives
 Large power
 V > 22 m/s Compressor, generator.
Dr. A. J. Makadia, Department of Mechanical Engineering

Unit-5 Belt, Ropes and Chains
5.3.1 Belt drives & its materials
Fig.5.1 - Types of Belts
5.3.1.1 Flat Belt

 Used in the industry where a moderate amount of power is transmitted.
 Dist. x ≤ 8m or 10m apart with 22 m/sec.
 Materials are leather, rubber, canvas, cotton & rubber Balata (higher strength than rubber belt).
5.3.1.2 V- Belt
 Used in the industry where a moderate amount of power to be transmitted.
 Connect the shaft up to 4m.
 Speed ratio can be up to 7 to 1 and belt speed 24 m/sec.
 Made of rubber impregnated fabric with the angle of V between 30° to 40°.
Note: In multiple V – belt drive all the belt should be stretch at the same rate so that load is equally
divided. When one of the selves of belt break, the entire set should be replaced at the same drive.
If one belt is replaced the new unworn and unstressed will be more tightly stretched and will more
with different velocity.
5.3.1.3 Ropes
 Used where a higher amount of power to be transmitted distance up to 30m apart.
 Operating speed is less than 3 m/sec.
 Materials for rope are cotton, hemp, manila or wire.
5.3.2 Types of Flat Belt Drives
5.3.2.1 Open Belt Drive
Fig.5.2 - Open belt drive

 An open belt drive is used when the driven pulley is desired to rotate in the same direction.
 Generally, the centre distance for open belt drive is 14 – 16 m. if the distance is too large, the belt
whips i.e. vibrate in a direction perpendicular to the direction of motion.
 For very shorter distance, the belt slips increase.
 While transmitting power, one side of the belt is more tightened (known as a tight side) as
compared to other (known as a slack side).
 In the case of horizontal drives, it is always desired that the tight side is at the lower side of two
pulleys. This is because the sag of the belt will be more on the upper side than the lower side. This
slightly increases the angle of wrap of the belts on the two pulleys than if the belt had been perfectly
straight between the pulleys.
 In case the tight side of the belt is on the upper side, the sag will be greater at the lower side,
reducing the angle of wrap and slip could occur earlier. This ultimately affects the power to be
transmitted.
5.3.2.2 Crossed Belt Drive
Fig.5.3 - Crossed belt drive
 A crossed belt drive is used when the driven pulley is to be rotated in the opposite direction to that
of the driving pulley.
 A crossed belt drive can transmit more power than an open belt drive as the angle of wrap is more.
 However, the belt has to bend in two different planes and it wears out more. To avoid this the shaft
should be placed at a max dist. 20 b where b = width of belt and speed should be less than 15 m
/sec.
5.3.2.3 Quarter Turn Belt Drive / Right Angle Belt Drive
Fig.5.4 - Quarter turn belt drive with guide pulley

 A guide pulley is used to connect two non-parallel shafts in such a way that they may run in either
direction and still making the pulley to deliver the belt properly in accordance with the law of belting.
 A guide pulley can also be used to connect even intersecting shaft also.
5.3.2.4 Belt Drive with Idler Pulley
Fig.5.5 - Belt drive with Idler pulley
 With constant use, the belt is permanently stretched in a little longer. This reduces the initial tension
in the belt leading to lower power transmission capacity. However, the tension in the belt can be
restored to the original value.
 A bell – crank lever, hinged on the axis of the smaller pulley, supports adjustable weights on its one
arm and the axis of a pulley on the other. The pulley is free to rotate on its axis and is known as an
idler pulley. Owing to weights on one arm of the lever, the pulley exerts pressure on the belt
increasing the tension and the angle of contact. Thus, the life of the belt is increased and the power
capacity is restored to the original value.
 The motion of one shaft can be transmitted to two or more than two shafts by using a number of
the idler pulley.
5.3.2.5 Compound Belt Drive / Intermediate Pulley
Fig.5.6 - Compound belt drive
 When it is required to have large velocity ratios, ordinarily the size of the larger pulley will be quite
big. However, by using an intermediate (counter-shaft) pulley, the size can be reduced.

5.3.2.6 Stepped / Cone Pulley Drive
Fig.5.7 - Stepped / Cone pulley drive
 A stepped cone pulley drive is used for changing the speed of the driven shaft while the main or
driving shaft runs at a constant speed.
 This is done by shifting the belt from one part of the step to the other.
5.3.2.7 Fast and Loose Pulley drive
Fig.5.8 - Fast and loose pulley drive
 Many times, it is required to drive several machines from a single main shaft. In such a case, some
arrangement to link or delink a machine to or from the main shaft has to be incorporated as all the
machines may not be operating simultaneously. The arrangement usually provided is that of using
a loose pulley along with a fast pulley.
 A fast pulley is keyed to the shaft and rotates with it at the same speed and thus transmits power.
 A loose pulley is not keyed to the shaft and thus is unable to transmit any power.
 Whenever a machine is to be driven, the belt is mounted on the fast pulley and when it is not
required to transmit any power, the belt is pushed to the loose pulley placed adjacent to the fast
pulley.

5.4 Law of Belting
 The law of belting states that centre line of the belt when it approaches a pulley must lie in the
midplane of that pulley. However, a belt leaving a pulley may be drawn out of the plane of the pulley.
 By following this law, non – parallel shafts may be connected by a flat belt.
 It should be observed that it is not possible to operate the belt in the reverse direction without
violating the law of belting. Thus, in the case of non – parallel shafts, motion is possible only in one
direction. Otherwise, the belt is thrown off the pulley.
 However, it is possible to run a belt in either direction on the pulley of two non – parallel or
intersecting shafts with the help of guide pulleys. The law of belting is satisfied.
5.4.1 Velocity Ratio of Belt Drive

 Velocity ratio is the ratio of the speed of driven pulley (N2) to that of a driving pulley (N1)
Let,
N1 = Speed of driving pulley
N2 = Speed of driven pulley
D1 = Diameter of the driving pulley
D2 = Diameter of the driven pulley
T = thickness of the belt
 Neglecting slip between belt & pulley and consider belt to be inelastic.
Let, the speed of belt on driving pulley = speed of belt on driven pulley
D1 N1 D2 N2
π = π
60 60
t t
(D1 + 2 ) N1 = (D2 + 2 ) N2
2 2
Or Velocity Ratio (VR)
N2 D1 + t
(VR) = =
N1 D2 + t
5.4.2 Velocity Ratio of Compound Belt Drive

Let,
D1, D2, D3, D4 = Diameter of pulley
N1, N2, N3, N4 = Speed of pulley
For pulley 1 & 2
N2 D1 Eq. (5.1)
=
N1 D2
For pulley 3 & 4
N4 D3 Eq. (5.2)
=
N3 D4
Multiplying Eq. (5.1) & Eq. (5.2)

N2 N4 D1 D3
× = ×
N1 N3 D2 D4
𝐍𝟒 𝐃𝟏 𝐃𝟑
= ×
𝐍𝟏 𝐃𝟐 𝐃𝟒
5.5 Slip of Belt

 Sometimes, due to insufficient frictional grip, there may be a chance of forwarding motion of belt
without carrying the driven pulley with it. This is called slip of belt and is expressed as a percentage.
 Result of slipping is reduced the velocity ratio of the system.
 Let,
S1% = Slip between driven & belt

S2% = Slip between belt & follower
Let the velocity of the belt passing over driver per second
π d1 N1 π d1 N1 S1 π d1 N1 S1 Eq. (5.3)
V= − × = [1 − ]
60 60 100 60 100
The velocity of the belt passing over follower per second
π d2 N2 S2 S2 Eq. (5.4)
=V −V∙ = V [1 − ]
60 100 100
From Eq. (5.3) & Eq. (5.4)
π d2 N2 π d1 N1 S1 S2
= [1 − ] × [1 − ]
60 60 100 100
N2 d1 S1 S2 S1 S2
= [1 − − ] … … … … . (Neglecting )
N1 d2 100 100 100 × 100
d1 (S1 + S2 )
= [1 − ]
d2 100
N2 d1 S
= [1 − ]
N1 d2 100
Where S = S1 + S2 – 0.01 S1S2 = Total Percentage of slip
𝐍𝟐 𝐝𝟏 + 𝐭 𝐒
= [𝟏 − ]
𝐍𝟏 𝐝𝟐 + 𝐭 𝟏𝟎𝟎
5.6 Creep of Belt

When the belt passes from slack side to tight side, a certain portion of the belt extends and it contracts
again when the belt passes from tight side to slack side. Due to these change of length, there is a relative
motion between belt & pulley surface. This relative motion is called “Creep”.
The total effect of creep is to reduce slightly the speed of the driven pulley or follower.
Considering the creep,
N2 d1 E + √σ2
Velocity ratio = [ ]
N1 d2 E + √σ1
Where
σ1 = Stress on the tight side of the belt
σ2 = Stress on the slack side of the belt
E = Young modulus for the belt material
5.7 Length of an Open Belt Drive
Fig.5.9 - 9 Length of an open belt drive
Let r1 , r2 = Radius of larger & smaller pulley.

x = Distance between centre of two pulley.
L = Total Length.
Let the length of the belt,
L = Arc GJE + EF + Arc FKH + GH

= 2 (Arc JE + EF + Arc FK) Eq. (5.5)
Let
π
Arc EJG = 2 Arc JE = 2 ( + α) ∙ r1
2
π
Arc FKH = 2 Arc FK = 2 ( − α) ∙ r2
2
r1 − r2
sin α =
x
EF = MO2 = √(O1 O2 )2 − (O1 M)2
= √(x)2 − (r1 − r2 )2
r1 − r2 2
= x √1 − ( )
𝑥
Expanding by Binominal Theorem

1 r1 − r2 2 1 r1 − r2 2
= x [1 − ( ) + ⋯⋯⋯] = x − ( )
2 𝑥 2 x

Putting value in Eq. (5.5)
π (r1 − r2 )2 π
∴ L = 2 [( + α) r1 + x − + ( − α) r2 ]
2 2x 2
π (r1 − r2 )2 π
= 2 [r1 ∙ + r1 ∙ α + x − + r2 ∙ − r2 ∙ α ]
2 2x 2
π (r1 − r2 )2
= 2 [ (r1 + r2 ) + α (r1 − r2 ) + x − ]
2 2x
(r1 − r2 )2
= π (r1 + r2 ) + 2 α (r1 − r2 ) + 2x −
x
r1 − r2
sin α =
[ x ]
α is small
∴ sin α = α
r1 − r2 (r1 − r2 )2
= π (r1 + r2 ) + 2 ( ) (r1 − r2 ) + 2x −
𝑥 x
(r1 − r2 )2 (r1 − r2 )2
= π (r1 + r2 ) + 2 + 2x −
x x
(r1 − r2 )2
L = π (r1 + r2 ) + 2x + In terms of Radius
x
𝛑 (𝐝𝟏 − 𝐝𝟐 )𝟐
𝐋 = (𝐝 + 𝐝𝟐 ) + 𝟐𝐱 + 𝐈𝐧 𝐭𝐞𝐫𝐦𝐬 𝐨𝐟 𝐝𝐢𝐚𝐦𝐞𝐭𝐞𝐫
𝟐 𝟏 𝟒𝐱
5.8 Length of Crossed Belt Drive
Fig.5.10 - Length of crossed belt drive
Let r1, r2 = Radius of larger & smaller pulley

x = Distance between centre of two pulley
L = Total Length

L = Arc GJE + Arc FKH + EF + GH Eq. (5.6)
π Eq. (5.7)
Arc GJE = 2 Arc JE = 2 ( + α) ∙ r1
2
π Eq. (5.8)
Arc FKH = 2 Arc HK = 2 ( + α) ∙ r2
2
EF = GH = MO2 = √(O1 O2 )2 − (O2 M)2
= √𝑥 2 − (r1 + r2 )2
r1 + r2 2
= x √1 − ( )
𝑥
Expanding by Binominal Theorem
1 r1 + r2 2
= x [1 − ( ) + ⋯⋯⋯]
2 𝑥
(r1 + r2 )2 Eq. (5.9)
= x−
2x
Putting value of Eq. (5.7), Eq. (5.8) & Eq. (5.9) in Eq. (5.6)
π (r1 + r2 )2 π
∴ L = 2 [r1 ( + α) + x − + r2 ( + α)]
2 2x 2
π (r1 + r2 )2 π
= 2 [r1 ∙ + r1 ∙ α + x − + r2 ∙ + r2 ∙ α ]
2 2x 2
π (r1 + r2 )2
=2 [ (r ) (r )
+ r2 + α 1 + r2 + x − ]
2 1 2x
(r1 + r2 )2
= π (r1 + r2 ) + 2 α (r1 + r2 ) + 2x −
x
sin α = α
As α is very small
[ r1 + r2 ]
sin α =
x
r1 + r2 (r1 + r2 )2
= π (r1 + r2 ) + 2 ( ) (r1 + r2 ) + 2x −
𝑥 x
(r1 + r2 )2 (r1 + r2 )2
= π (r1 + r2 ) + 2 + 2x −
x x
(r1 + r2 )2
L = π (r1 + r2 ) + 2x + In terms of Radius
x
𝛑 (𝐝𝟏 + 𝐝𝟐 )𝟐
𝐋 = (𝐝 + 𝐝𝟐 ) + 𝟐𝐱 + 𝐈𝐧 𝐭𝐞𝐫𝐦𝐬 𝐨𝐟 𝐝𝐢𝐚𝐦𝐞𝐭𝐞𝐫
𝟐 𝟏 𝟒𝐱

5.9 Ratio of Friction Tensions
5.9.1 Flat Belt
Fig.5.11 - Ratio of Friction Tensions for Flat Belt
T1 = Tensions on tight side.

T2 = Tensions on slack side.
θ = Angle of Lap of the belt over the pulley.
μ= Coefficient of friction between belt & pulley.
Consider a short length of belt PQ subtending an angle of δθ at the centre of the pulley.
R = Normal (Radial) reaction between element length of belt & pulley.
T = Tension on the slack side of the element.
δT = increase in tension on the tight side than that of the slack side.
T + δT = Tension on the tight side of the element.
Tensions T and (T + δT) act in directions perpendicular to the radii drawn at the end of elements. The
friction force F = μR will act tangentially to the pulley rim resisting the slipping of the elementary belt on
the pulley.
 Resolving the forces in the tangential direction (Horizontally),
δθ δθ
μR + T cos − (T + δT) cos =0
2 2
μR + T − (T + δT) = 0
As δθ is small
[ δθ ]
cos ≈1
2
δT Eq. (5.10)
R=
μ
 Resolving the forces in Radial Direction (Vertically),
δθ δθ
R − T sin − (T + δT) sin =0
2 2

δθ δθ δT ∙ δθ
R − T − T − =0
2 2 2
As δθ is small
δθ δθ
[ sin 2 ≈ 2 ]
δT ∙ δθ
→ Neglect
2
Tδθ Eq. (5.11)

R=2 = T δθ
2
Comparing Eq. (5.10) and Eq. (5.11)
δT
= T δθ
μ
δT
∴ = μ δθ
T
Integrating between proper limits,
T1 θ
δT
∫ = ∫ μ δθ
T
T2 0
T1
∴ log e = μθ
T2
Or taking a log to the base 10

𝐓𝟏 T1
= 𝐞𝛍𝛉 2.3 log = μθ
𝐓𝟐 T2
Note: The above relation is valid only when the belt is on the point of slipping on the pulleys.
5.9.2 V – Belt or Rope
Fig.5.12 - Ratio of Friction Tensions for V-Belt or Rope

In the case of v belt or rope, there are two normal reactions, so the radial reaction is equal to
2R sin α
Thus total friction force = 2F = 2μR
Resolving the forces tangentially,
δθ δθ
2μR + T cos − (T + δT) cos =0
2 2
2μR + T − T − δT = 0
As δθ is small
[ δθ ]
cos ≈1
2
δT = 2μR Eq. (5.12)
Resolving the forces radially,

δθ δθ
2R sin α − T sin − (T + δT) sin =0
2 2
δθ δθ δT ∙ δθ
2R sin α − T − T − =0
2 2 2
As δθ is small
δθ δθ
sin ≈
2 2
δT ∙ δθ
[ 2 → Neglect]
Tδθ
2R sin α = 2
2
Tδθ Eq. (5.13)
∴R=
2 sin α
From Eq. (5.12) and Eq. (5.13)
Tδθ δT μ δθ
δT = 2 μ or =
2 sin α T sin α
Integrating between proper limits,
T1 θ
δT μ δθ
∫ = ∫
T sin α
T2 0
T1 μθ
∴ log e =
T2 sin α
𝐓𝟏
= 𝐞𝛍𝛉⁄sin α = 𝐞𝛍𝛉 𝐜𝐨𝐬𝐞𝐜𝛂
𝐓𝟐

Notes:
 The expression is similar to that for a flat belt drive except that μ is replaced byμ⁄sin θ, i.e., the
coefficient of friction is increased by 1⁄sin θ. Thus, the ratio T1 ⁄T2 is far greater in the case of V –
belts & ropes for the same angle of lap θ and coefficient of friction μ.
 Above expression is derived on the assumption that the belt is on the point of slipping.
5.10 Power Transmitted by a belt

Let
T1 = Tensions on tight side.
T2 = Tensions on slack side.
V = Linear velocity of the belt
P = Power transmitted
Distance moved
P = Net Force ×
second
= (T1 − T2 ) V
Note:-This relation gives the power transmitted irrespective of the fact whether the belt is on the point of
slipping or not.
If it is the relationship between T1 and T2 for a flat belt is given by T1⁄T2 = eμθ. If it is not, no particular
relation is available to calculate T1 and T2 .
5.11 Angle of Contact or Angle of Lap
5.11.1 Open Belt Drive
Fig.5.13 - Open Belt Drive
r1 = Radius of the larger pulley

r2 = Radius of the smaller pulley
x = Centre distance between two pulley

Angle of contact (θ)
θ = (180 − 2α)°
π
= (180 − 2α) Radian
180
r1 − r2
Where sin α = ( )
x
5.11.2 Cross Belt Drive
Fig.5.14 - Cross Belt Drive
Angle of contact (θ)

θ = (180 + 2α)°
π
= (180 + 2α) Radian
180
r1 + r2
Where sin α = ( )
x
5.12 Centrifugal effect on Belt
Fig.5.15 - Centrifugal effect on Belt
 While in motion, as a belt passes over a pulley, the centrifugal effect due to its own weight tends
to lift the belt from the pulley.

 The centrifugal force produces equal tensions on the two side of the belt, i.e., on the tight and on
the slack side.
 Let,
m = mass of belt per meter length (Kg/m)

v = Linear velocity of belt (m/sec)
r = Radius of pulley
TC = Centrifugal tension on tight side & Slack side
FC = Centrifugal force
FC = mass of element × Acceleration
= (Length of element × mass per unit length) × Acc.

v2 Eq. (5.14)
= (r δθ × m) ×
r
From figure resolving forces radially,
δθ
FC = 2 TC sin
2
δθ
= 2 TC
2
δθ
is small
[ 2 ]
δθ δθ
sin ≈
2 2
FC = TC δθ Eq. (5.15)
From Eq. (5.14) and Eq. (5.15),
TC δθ = m v 2 δθ
∴ 𝐓𝐂 = 𝐦 𝐯 𝟐
∴ To depend on the only velocity of belt and mass of the belt.

centrifugal Tension TC
Also centrifugal stress in belt = =
c⁄s Area of belt a
Or
TC = σ ∙ A (Max tension in belt)
Total Tension on tight side = Friction tension + Centrifugal tension
T = T1 + TC
Total Tension on slack side = T2 + TC

5.13 Maximum Power transmitted by a belt
If it is desired that belt transmit maximum power, the following two conditions must be satisfied.
1. Larger tension must reach the maximum permissible value for the belt.
2. The belt should be on the point of slipping i.e., the maximum frictional force is developed in the belt.
Let
P = (T1 − T2 ) ∙ v
T2
= T1 (1 − )∙ v
T1
1
= T1 (1 − )∙ v
T
(T1 )
2
T1
= eμθ
T2
1
[ 1 − = k constant]
eμθ
= T1 k ∙ v
= ( T − TC ) ∙ k ∙ v
T = T1 + TC
[ ]
∴ T1 = T − TC
= kTv − TC ∙ kv
= kTv − (m v 2 ) ∙ kv
P = kTv − kmv 3
Here maximum tension T in the belt should not exceed permissible value. Hence treating T as constant
and differentiating the power with respect to v and equating the same equal to zero.
dP
∴ = kT − 3 v 2 (k m) = 0
dv
∴ kT = 3 v 2 k m
T = 3 mv 2
𝐓
T = 3 TC or 𝐓𝐂 =
𝟑
For maximum power transmission, the centrifugal tension in the belt is equal to 1/3 of the maximum
allowable belt tension and belt should be on the point of slipping.
Also T = T1 + TC

∴ T1 = T − TC
T 2T
=T− =
3 3
Also T = 3TC
= 3 ∙ m v2
T
∴ Vmax = √
3m
5.14 Initial Tension in the Belt

When a belt is first fitted to a pair of the pulley, an initial tension T0 is given to the belt when the system is
stationary. When transmitting power, the tension on tight increases to T1 and that on slack side decreases
to T2 .
If it is assumed that the material of the belt is perfectly elastic i.e., the strain in the belt is proportional to
stress in it and the total length of the belt remains unchanged, the tension on the tight side will increase
by the same amount as the tension on the slack side decreases. If the change in the tension is δT,
Tension on the tight side T1 = T0 + δT

Tension on the slack side T2 = T0 − δT
T1 + T2
∴ T0 = = Mean of tight side & 𝑠𝑙𝑎𝑐𝑘 𝑠𝑖𝑑𝑒 𝑡𝑒𝑛𝑠𝑖𝑜𝑛𝑠
2
5.14.1 Initial tension with centrifugal tensions

Total tension on tight side = T1 + TC
Total tension on slack side = T2 + TC

Let,
T1 + T2 (T1 + TC ) + (T2 + TC ) T1 + T2 + 2TC
T0 = = =
2 2 2
T1 + T2
T0 = = TC
2
∴ T1 + T2 = 2(T0 − TC )
T1
[Let = eμθ = k]
T2
k T2 + T2 = 2 (T0 − TC )
(T0 − TC )
T2 = 2
k +1

Let,
T1 = T2 ∙ k
2 k (T0 − TC ) Eq. (5.16)
T1 =
(k + 1)
2 k (T0 − TC ) (T0 − TC )
∴ T1 − T2 = − 2
(k + 1) k +1
2 (k − 1)(T0 − TC )
T1 − T2 =
(k + 1)
Power transmitted (P) = (T1 − T2 )v
2 (k − 1)(T0 − TC )
= ∙v
(k + 1)
2 (k − 1)(T0 − m v 2 )
= ∙ v
k+1
2 (k − 1)(T0 v − m v 3 )
P=
k+1
To find the condition for maximum power transmission,
dP
= T0 − 3mv 2 = 0
dv
∴ T0 = 3mv 2
T0
∴v=√
3m
When the belt drive is started, v = 0 and thus TC = 0 (TC = mv 2 )

2 k T0 Eq. (5.17)
T1 =
k +1
5.15 Crowning of Pulley
Fig.5.16 - Crowning of Pulley

Pulleys are provided with a slight dwell to prevent the belt from running off the pulley. This is known as the
crowning of the pulley.
Crowning may be tapered or rounded. Normally crown height of 10 mm / m face width is provided.
5.16 Advantages & Disadvantages of V – Belt drive over Flat Belt drive
5.16.1 Advantages
 V - Belt drive gives compactness due to a small distance.
 The drive is positive because slip is less.
 V – Belts are made endless, no joint so smooth drive.
 Longer life 3 – 5 year.
 Easily installed & removed.
 The high-velocity ratio may be obtained.
 Power transmission is more due to wedging action of the belt in the groove.
 V – Belt may be operated in either direction.
5.16.2 Disadvantages
 V – Belt drive can’t use for a large distance.
 V – Belts are not so durable as flat belts.
 Construction of pulley for V – Belt is more complicated than the pulleys for a flat belt.
 Since V – Belts are subjected to a certain amount of creep, so they are not suitable for constant
speed application such as synchronous machines, timing devices etc.
 Belt life is effect with temperature changes, improper belt tension and mismatching of belt length.
 The centrifugal tension prevents the use of V – Belts at speed below 5 m/s and above 50 m/sec.
5.17 Rope drive

 Rope drive is widely used where a large amount of power is to be transmitted from one pulley to
another over a considerable distance.
 Frictional grip in case of rope drives is more than V – drives.
 The number of separate drives may be taken from one driving pulley.
5.17.1 Types of Rope Drive
5.17.1.1 Fibre Rope Drive

 They are made from Fibrous material each as Hemp, Manila and cotton.
 Manila ropes are more durable and stronger than cotton rope. (Hempropes have less strength
compared to Manila ropes).
 Cotton ropes are costlier than Manila ropes.

Fig.5.17 - Fibre Rope
5.17.1.2 Wire Rope Drive
Fig.5.18 - Wire Rope
 When a large amount of power is to be transmitted over a long distance (≅ 150 m apart) then wire
ropes are used.
 The wire ropes are used in elevators, mine hoists, crane, conveyors, and suspension bridges.
 The wire rope runs on grooved pulleys, but they rest on the bottom of the grooves and are not
wedged between the sides of the grooves.
 Wire ropes are made from cold drawn wires, various materials are wrought iron, cast steel, alloy
steel, copper, bronze, aluminium, alloys, S.S. etc.
5.17.1.2.1 Construction & Designation of Wire rope drive
Fig.5.19 - Construction & Designation of Wire rope drive

Fig.5.20 - Sheave for Fibre rope
Fig.5.21 - Sheave for Wire rope

T1
Ratio of Driving tensions = 2.3 log = μ θ cosecβ
T2
5.18 Chain Drive

 A chain is regarded in between the gear drive and the belt drive. Like gears, chains are made of
metal, so it requires lesser space and gives a constant velocity ratio. As a belt, it is used for longer
centre distances.
Advantages
1. Constant velocity due to no-slip, so it is a positive drive.
2. No effect on overload on the velocity ratio.
3. Oil or grease on the surface does not affect the velocity ratio.
4. Chains occupy less space as they made of metals.
5. Lesser loads are put on the shaft.
6. High transmission efficiency due to “No-slip”.
7. Through one chain only motion can be transmitted to several shafts.
Disadvantages
1. It is heavier as compared to the belt.
2. There are gradual stretching and an increase in the length of chains. From time to time some
of its links have to be removed.
3. Lubrication of its parts is required.
4. Chains are costlier compared to belts.
5.18.1 Relation between Pitch and Pitch circle diameter for Chain
Fig.5.22 - Relation between Pitch and Pitch circle diameter for Chain
 The distance between roller centres of two adjacent links is known as pitch (p) of a chain.
 A circle through the roller centre of wrapped chain around a sprocket is called pitch circle and its
diameter as pitch circle diameter (d).
Let,
T = No. of teeth on the sprocket
∅ = Angle subtended by the chord of a link at the centre of the sprocket
r= Radius of the pitch circle
Let,
∅ p⁄2 ∅ p
sin = ∴ sin =
2 r 2 2r
∅ 360° 180°
∴ p = 2r sin = 2r sin ( ) = 2r sin ( )
2 2T T
p p 180°
∴ r= = cosec ( )
180° 2 T
2 sin ( T )
or
𝟏𝟖𝟎°
𝐝 = 𝐩 𝐜𝐨𝐬𝐞𝐜 ( )
𝐓
5.18.2 Chain Length

 Length of a chain may be calculated the same way as for open belt drive.
R & r = Radius of the pitch circle of two sprockets having T & t teeth.
C = centre distance between sprocket = k ∙ p
p = Pitch of chain
Let,
(R − r)2
L = π (R + r) + 2C +
C
Let
p 180°
R= cosec ( )
2 T
p 180°
[𝑟 = 2
cosec (
t ]
)
2
p 180° p 180°
(2 cosec ( T ) − 2 cosec ( t ))
pT + pt
L= + 2(kp) +
2 kp
also circular pitch (p)

πD π2R
p= =
T T
pT
∴ πR =
2
pT + pt
∴ π (R + r) =
2
[ Also C = k ∙ p ]
2
180° 180°
(cosec ( T ) − cosec ( t ))
T+t
=p + + 2k
2 4k
[ ]
5.18.3 Classification of Chains
5.18.3.1 Hoisting Chain
Fig.5.23 - Hoisting Chain
 Hoisting chain includes an oval link and stud link chains. An oval link is a common form of hoisting
chain. It consists of an oval link and is also known as coil chain. Such chains are used for lower
speed only.
5.18.3.2 Conveyor Chain

 Conveyor chain may be detachable or hook type or closed joint type. The sprocket teeth are so
shaped that the chain should run onto and off the sprocket smoothly without interference.
 Such chains are used for low-speed agricultural machinery. The material of the link is usually
malleable cast iron. The motion of the chain is not very smooth.
Fig.5.24 - Conveyor Chain
5.18.3.3 Power transmission chain

 These chains are made of steel in which the wearing parts are hardened. They are accurately
machined and run on carefully designed sprockets.
a. Block Chain
Fig.5.25 - Block Chain
 This type of chain is mainly used for transmission of power at low speeds. Sometimes they are
also used as conveyor chains in place of malleable conveyor chains.
b. Roller Chain
Fig.5.26 - Roller Chain
 A bushing is fixed to an inner link whereas the outer link has a pin fixed to it. There is only sliding
motion between pin and bushing. The roller is made of hardened material and is free to turn on the
bushing.
c. Silent Chain (Inverted tooth chain)
Fig.5.27 - Silent Chain
 Though roller chain can run quietly at fairly high speed. The silent chains are used where maximum
quietness is desired. Silent chains do not have rollers. The links are so shaped as to engage directly
with the sprocket teeth. The included angle is either 60° or 75°.

5.19 Problems
Ex. 5.1 A shaft runs at 80 rpm and drives another shaft at 150 rpm through a belt drive. The
diameter of the driving pulley is 600 mm. determine the diameter of the driven pulley in
the following cases.
a) Neglecting belt thickness.
b) Taking belt thickness as 5mm.
c) Assuming for case (ii) total slip of 4%.
d) Assuming for case (ii) a slip of 2% on each pulley.
N1  80 rpm ,D1  600 mm

N2  150 rpm ,D2  ?
Case (i) Neglected belt thickness
N2 D1 N1 D1 80  600
 D2    320 mm
N1 D2 N2 150
Case (ii) Belt thickness = 5mm
N2 D1  t N1 D1  t 
 D2  t 
N1 D2  t N2
80  605
D2  5  D2  317.67 mm
150
Case (iii) Total Slip is 4%
N2 D1  t  S 
 1
N1 D2  t  100 

150  600  5  4 
 1 D2  304.76 mm
80 D2  t  100 

Case (iv) Slip 2% on each pulley
N2 D1  t  S 
 1 
N1 D2  t  100 
S  S1  S2  0.01 S1 S2 
 
  2  2  0.01  2  2 
  3.96
 

150  600  5  3.96 
 1 D2  304.88 mm
80 D2  t  100 
Ex. 5.2 Two parallel shafts connected by a crossed belt, are provided with pulleys 480 mm and
640 mm in diameters. The distance between the centre line of the shaft is 3 m. Find by how
much the length of the belt should be changed if it is desired to alter the direction of
rotation of the driven shaft.

R = 320 mm
r = 240 mm
X = C = 3 mtr
For cross belt drive,

  180  2 
180
 R  r 320  240 0.320  0.240 

sin   C  3

3 
Lcross     2  R  r   2C Cos  
   10.75  10 45' 
  0.1878 rad 
Lcross     2  0.1878   0.32  0.24   2  3 cos 10.75

 7.865mtr.
For open belt drive,
L open   r1  r2   2 r1  r2   2x cos   r1  r2 

sin   X 
 
R  r 
2
0.320  0.240 
L open   R  r    2C  
C  3 
 
 0.32  0.24 
2    1 31' 
   0.32  0.24    2 3 Angle is small approx. 
3  
relation canbe used. 
 7.761mtr.  
 
 
Let the length of belt reduced by,
Lcross  Lo  7.865  7.761

 0.104 mtr.
Ex. 5.3 A belt runs over a pulley of 800 mm diameter at a speed of 180 rpm. The angle of the lap
is 165° and the maximum tension in the belt is 2kN. Determine the power transmitted if the
coefficient of friction is 0.3.
T1  2000 N
d  0.8 mtr.
N  180 rpm

  165  rad
180
 2.88 rad
  0.3
Let,

dN   0.8  180
V   7.54 m / sec
60 60
T1
2.3 log10  
T2
T 
2.3log10  1   0.3  2.88
 T2 
 T  2000 N 
T1 1 
  2.37 T  1   843N
T 2000
T2  
 
2
2.37 2.37
Power   T1  T2  v
  2000  843  7.54
 8724 W
P  8.724 kW
Ex. 5.4 A casting weights 6 kN and is freely suspended from a rope which makes 2.5 turns round
a drum of 200 mm diameter. If the drum rotates at 40 rpm, determine the force required
by a man to pull the rope from the other end of the rope. Also, find the power to raise the
casting. The coefficient of friction is 0.25.
W  T1  6000 N
  2.5  2  15.70 rad
d  0.20 mtr.
N  40 rpm
  0.25
T2  ?
P ?
Let,
dN   0.2  40
V   0.419 m / sec
60 60
T1
2.3log10    0.25  15.70
T2
T1
  50.87  T2  117.93N
T2
Power   T1  T2  v
  6000  117.93  0.419
 2464 Watt
P  2.46 kW

Ex. 5.5 A belt drive transmits 8 kW of power from a shaft rotating at 240 rpm to another shaft
rotating at 160 rpm. The belt is 8 mm thick. The diameter of smaller pulley is 600 mm
and the two shafts are 5 m apart. The coefficient of friction is 0.25. If the maximum
stress in the belt is limited to 3 N/mm2. Find the width of the belt for (i) open belt drive
and (ii) crossed belt drive.
P  8  103 watt
N1  240 rpm , d1  0.600 m (Smaller pulley)
N2  160 rpm
x  5m
  0.25
t  8 mm
  3N / mm2
Let,
N1 d1  N2 d2
N1 d1 240  0.6
d2    0.900 mtr. (bigger pulley)
N2 160
(i) Open Belt drive

Angle of contact   180  2 
180  r  r 0.450  0.300 
 sin   1 2  
 180  2 1.71   X 5 
180    1.71 
  3.08 rad
Let,
T1
2.3log10    0.25  3.08
T2
T1
  2.16
T2
  d1 N1 
Velocity v  60 
Power   T1  T2  v  
   0.6  240 
8000   T1  T2  7.54   
 T1  T2  1061  60 
 v  7.54 m / sec 
 
 
Let,
Max tension T1   b t  T1 
1975   b t   2.16 & T1  T2  1061
1975  3  b  8  T2 
b  82.29 mm T  914 N ,T  1975N 
1 2 

(ii) Cross belt drive

Angle of contact   180  2 
180  r  r 0.450  0.300 
 sin   1 2  
 180  2  8.62    X 5 
180    8.62 rad 
  3.443rad
T1
2.3log10    0.25  3.443
T2
T1
  2.36
T2
Let,
 T1 
T1  T2  1061 &  2.36 
Max tension T1   b t  T2 
 T  780 N,T  1840 N 
 2 1 
1840  3  b  8
b  76.6 mm
Ex. 5.6 A 100 mm wide and 10 mm thick belt transmits 5 kW of power between two parallel shafts.
The distance between the shaft centres is 1.5 m and the diameter of the smaller pulley is
440 mm. The driving and the driven shafts rotate at 60 rpm and 150 rpm respectively. The
coefficient of friction is 0.22. Find the stress in the belt if the two pulleys are connected by
(i) an open belt drive (ii) a cross belt drive.
b  100 mm , t  10 mm
P  5  103 watt
x  1.5m
N1  60 rpm
N2  150 rpm , d2  440 mm
  0.22
open  ?
cross  ?
Let,
N1 d1  N2 d2
N2 d2 150  440
d1  
N1 60
d1  1100 mm
(i) Open Belt drive,

 r1  r2 550  220 
 sin   X 
Angle of contact   180  2  1.5 
180  
  0.55  0.22 
 180  2 12.7     
180  1.5 
  2.697 rad
   12.70 
 
 
Let,
T1
2.3log10    0.22  2.697
T2
T1
  1.81 ______(1)
T2
  t  2  N2 
v  r    r  2  60 
   
Power   T1  T2  v considering thickness of 
 
5  103   T1  T2  3.535 belt 
 T1  T2  1414.5N _____(2)   3535mm / sec 
 
v  3.535m / sec 
 
 
From equation (1) & (2)
T1  3160.8 N
T2  1746.2 N
Max tensionin the belt T   b t

3160.8   100  10
  3.16 N / mm2
(ii) Cross Belt drive,
  r  r 0.55  0.22 
Angle of contact   180  2  sin   1 2  
180  X 1.5 
   30.88 

 180  2  30.88  
180
  4.22
Let,
T1
2.3log10    0.22  4.22
T2
T1
  2.53
T2

Power   T1  T2  v
 T1 
T1  T2  1414.5 &  2.53 
5000   T1  T2  3.535  T2 
 T  924.5N, T  2339 N 
 2 1 
T1  T2  1414.5N

2339   100  10
  2.339 N / mm2
Ex. 5.7 An open belt drive is required to transmit 10 kW of power from a motor running at 600 rpm.
The diameter of the driving pulley is 250 mm. Speed of the driven pulley is 220 rpm. The
belt is 12 mm thick and has a mass density of 0.001 g/mm 2. Safe stress in the belt is not
to exceed 2.5 N/mm2. Two shafts are 1.25 m apart. Take µ = 0.25. Determine the width of
the belt.
P  10  103 watt
N  600 rpm
x  1.5m
Speed of Driving pulley N1  600 rpm
Diameter of driving pulley d1  250 mm
Speed of Drivenpulley N2  220 rpm
t  12 mm
  0.001 g / mm3  3
1
kg 
 10   103 kg / m3
3 3
10  10 3
m 3
  2.5N / mm  2.5  10 N / m
2 6 2
x  1.25m
  0.25
b ?
Let,
N1 d1  N2 d2
N1 d1 600  250
d2  
N2 220
d2  681.81mm
Let,
 t  t  2 N
v  r      r  
 2  2  60
 12  2   600
  125   
 2  60
 8230 mm / sec
v  8.23 m / sec

Let,
P   T1  T2  v
10  103   T1  T2  8.23
 T1  T2   1215 _____(1)
Let,
T1
2.3log10  
T2
 0.25  2.79
T1
  2.01 ______(2)
T2
openbelt drive 
 
  180  2   rad where sin   r1  r2 
 180 X 
 
  180  2  9.94    340.90  125 

   180 1.25 
  2.79   9.94 rad 
 
T2  1203N
T1  2418 N
Centrifugal Tension (Tc)
m  Mass of belt / unit length 

  volume per unit length   
 
TC  m v2
  x sec tional area  length   
 (12b ) (8.23)2  
TC  812.8b N   width  thickness  length   
  b  0.012  1  103 
 
  12 b 
 2.5  106  b  0.012
 30,000 b
Let,
T  T1  TC
30,000b  2418  812.8b

b  0.0828 m
b  82.8 mm

Ex. 5.8 Two parallel shafts that are 3.5 m apart are connected by two pulleys of 1 m and 400 mm
diameter. The larger pulley being the driver runs at 220 rpm. The belt weight 1.2 kg/meter
length. The maximum tension in the belt is not to exceed 1.8 kN. The coefficient of friction
is 0.28. Owing to slip on one of the pulleys, the velocity of the driven shaft is 520 rpm only.
Determine:
(i) Torque on each shaft
(ii) Power transmitted
(iii) Power lost in friction
(iv) The efficiency of the drive

x  3.5m
d1  1m, N1  220 rpm
d2  0.400 m, N2  520 rpm
m  1.2 kg / m
t  1.8  103 N
  0.28
Let,
 d1 N1
v
60
  1  220

60
v  11.52 m / sec  10
TC  m v2
 1.2 (11.52)2
TC  159 N

  180  2  rad
180
r1  r2
 where sin  
 180  2 (4.91) X
180
  2.97 rad 0.5  0.2

3.5
  4.91
Let,
Max Tension 
T T  T  T 
2.3log10 1    0.28  2.97  1 C 
T2  
1.8  10  T1  159
3

 T  1641N 
 1 
 T2  714 N 
T1
  2.299
T2
1.
Torque onlarger pulley   T1  T2  r1

 (1641  714)  0.5
TL  463.5 N  m
Torque on smaller pulley   T1  T2  r2
 (1641  714)  0.200
TS  185.4 N  m
2.
Power transmitted P   T1  T2  v
 (1641  714)  11.52
 10679 watt
P  10.679 kw
3. Power lost in friction,
2  N1T1 2   220  463.5

Input Power Pin    10678 watt
60 60
2  N2 T2 2   920  185.4
Output Power Pout    10096 watt
60 60
Power Loss  10678  10096  582 watt
4. The efficiency of the drive (  ) ,
Output Power 10096

   0.945  94.5 %
Input Power 10678
A V- belt drive with the following data transmits power from an electric motor to
Ex. 5.9
compressor:
Power transmitted = 100 kW
Speed of the electric motor = 750 rpm
Speed of compressor = 300 rpm
Diameter of compressor pulley = 800 mm
Centre distance between pulleys = 1.5 m
Max speed of the belt = 30 m/sec
Mass of density = 900 kg / m3
C/s area of belt = 350 mm2
Allowable stress in the belt = 2.2 N / mm2
Groove angle of pulley = 38°= 2β
Coefficient of friction = 0.28
Determine the number of belts required and length of each belt.
Solution: Let,
N1 d1  N2 d2
N2 d2 300  800
d1    320 mm
N1 750
Let centrifugal tension (TC)

m  Mass of belt / length 
  Area  length  density 
 
TC  m v2  6 
  350  10  1  900 
 0.315(30)2  283.5N   0.315kg /m 
 
v  30 m / sec 
Let Maximum Tension in belt,
T  b t
 2.2  350
T  770 N
Let,
T  T1  TC
openbelt drive 
 r r 
 T1  T  TC   180  2   rad sin   1 2 
 180 X 
 770  283.5  
T1  486.5N    180  2  9.20    400  160 
  180 
 1.5 
  2.82 rad   9.20 rad 

Let,
T1
2.3 log10   cosec
T2
0.28  2.82

sin19
T1
  11.3 T2  43.1N
T2
Power   T1  T2  v
 (486.5  43.1 ) 30
 13302 Watt
P  13.3kW
Totalpower transmitted 100

No. of belt    7.51  8 belts
Power transmitted / belt 13.3
Length of belt drive (using approximate relation),
r  r 
2
L o   r1  r2   2x  1 2
x
 0.4  0.16 
2
   0.4  0.16   2 (1.5) 

3
Lo  4.79 m
Ex. 5.10 Determine the maximum power transmitted by a V – belt drive having the included v –
groove angle of 35°. The belt used is 18 mm deep with 18 mm maximum width and weight
300 g per metre length. The angle of the lap is 145° and the maximum permissible stress
is 1.5 N/mm2. µ = 0.2.
V Belt Drive
2  35
t  18 mm, w  18 mm
m  0.3kg / m

  145  rad  2.53 rad
180
  1.5  106 N / m2
  0.2
Pmax  ?
Let,

 1.5  18  18
 486N
T
Velocity for Max Power v 
3m
486

3  0.3
v  23.23m / sec
Now,
T1
2.3 log10   cosec
T2
0.2  2.53

sin 17.5 
T1
  5.39
T2
Let,
 
OR 
Centrifugal Tension TC  m v 2
 
 0.3(23.23)2  162 N  Max Tension condi. 
T  T  486  162 N
 C 3 3 
Let,
T  T1  TC

T1  T  TC  486  162  324 N
T1
  5.39 T2  60.2N
T2
Max Power P   T1  T2  v
  324  60.2  23.23
 6128.074 Watt
P  6.12 kW
Ex. 5.11 The grooves on the pulleys of a multiple rope drive have an angle of 50° and accommodate
rope of 22 mm diameter having a mass of 0.8 kg/metre length for which a safe operating
tension of 1200 N has been laid down. The two pulleys are of equal size. The drive is
designed for max power conditions. Speeds of both pulleys are 180 rpm. Assuming µ =
0.25. Determine the diameter of pulleys and no. of ropes when power is transmitted 150
kW.
Rope Drive
2  50
d  dia. of rope  22 mm
m  0.8 kg / m
T  1200 N
d1  d2  dia. of pulley   180
Max Power conditions
N1  N2  180 rpm
  0.25
P  150  103 Watt
d1  d2  ?
No. ofRopes  ?
For Max Power Conditions....

2 2
T1  T   1200  800 N
3 3
T  T1  TC
TC  T  T1  1200  800  400N
OR 
TC  m v 2  T 1200 
400  0.8 v2 v   
 v  22.36 m / sec  3m 3  0.8 
  22.36 m / sec 
Let,
 D1 N1
Velocity v 
60
 D1  180
23.36  D1  2.37m
60

Let,
T1
2.3 log10   cosec
T2
   1
 0.25   180  
 180  sin25
T1
  6.42 T2  124.61N
T2
Power P   T1  T2  v
  800  124.61  22.36
P  15.10 kW / Rope
TotalPower 150 kW
No. of Ropes    9.93  10 Ropes
Power / Rope 15.10 kW
The following data relate to a rope drive
Ex. 5.12
Power transmitted = 20kW
Diameter of pulley = 480 mm
Speed = 80 rpm
Angle of lap on smaller pulley = 160°
No. of Ropes =8
Mass of Rope / m length = 48 G2 kg
Limiting working tension = 132 G2
Coefficient of friction = 0.3
Angle of groove = 44°
If G is the girth of rope in m, determine the initial tension and diameter of each rope.
P  20  103 Watt
d  dia. of pulley  0.48 m
N  80 rpm

  160  rad
180
n  No. of Ropes  8
m  48 G2 kg / m
T  132 G2 kN
  0.3
2 44
T0  ?
dia. of Rope  ?
Let,
20  103
Power transmitted / Rope   2500 Watt
8
 dN   0.48  80
Velocity of Rope    2.01m / sec
60 60
Let,
Power P   T1  T2  v
2500   T1  T2  2.01
T1  T2  1244 N
Let,
T1
2.3 log10   cosec
T2
   1
 0.3   160  
 180  sin22
T1 
Solving equation

  9.38 T1  1392.44 
T2 T2  148.44
 

1.
T1  T2
Initial Tension T0   770.44 N
2
2. Diameter of Rope (D)
Total Tension T  T1  TC
132  103  G2  1392.44  48 G2 (2.01)2
G  0.1028
Now Girth(Circumference) of Rope   D

0.1028   D D  0.032 m
Ex. 5.13 2.5 kW power is transmitted by an open belt drive. The linear velocity of the belt is 2.5
m/sec. The angle of the lap on the smaller pulley is 165°. The coefficient of friction is 0.3.
Determine the effect on power transmission in the following cases:
(i) Initial tension in the belt is increased by 8%.
(ii) Initial tension in the belt is decreased by 8%.
(iii) The angle of the lap is increased by 8% by the use of an idler pulley, for the same
speed and the tension on the tight side.
(iv) Coefficient of friction is increased by 8% by suitable dressing to the friction surface
of the belt.
Solution: Let,
Power P   T1  T2  v
2500   T1  T2  2.5
T1  T2  1000N ______(1)

Also,
T1 
2.3log10    0.3  165 
T2 180
T1
  2.37 _____(2)
T2
By Solving,
T2  729.9 N
T1  1729.92 N
T1  T2
Initial Tension T0   1229.9 N
2
Initial Tension increased by 8%,
T0  1229.9  1.08  1328.30N
T1  T2
Or T0 
2
T1  T2
1328.30   T1  T2  2656.60 N _____(3)
2
As µ and θ remain unchanged,
T1
  2.37 _____(4)
T2
By solving equation (3) & (4),
T1  1868.3N
T2  788.30 N
Let,
Power P   T1  T2  v
 1868.3  788.30  2.5

P  2.7kW
2.7  2.5
increase inpower   0.08  8%
2.5
Initial Tension decreased by 8%,
T0  1229.9  1  0.08   1131.50 N
T1  T2
Or T0 
2
T1  T2
1131.50   T1  T2  2263N _____(5)
2
As µ and θ remain unchanged,

T1
  2.37 _____(6)
T2
T1  1591.5N
T2  671.5N
Let,
Power P   T1  T2  v
 1591.5  671.5 2.5

P  2.3kW
2.5  2.3
decrease inpower   0.08  8%
2.5
The angle of Lap (θ) is increased by 8% with the same speed and T1,
Let,
T1   
2.3log10    0.3   165   1.08 
T2  180 
T1
  2.54
T2
T1 is the same.
T1  1729.92 N
T2  681.07 N
Power P   T1  T2  v
 1729.92  681.07 2.5

P  2.62kW
2.62  2.5
increase inpower   0.048  4.8%
2.5
Coefficient of friction is increased by 8%,
Let,
T1
2.3log10  
T2

  0.3  1.08   165 
180
T1
  2.54 _____(7)
T2
Let,
T1  T2
T0   1229.9
2
T1  T2  2459.8N _____(8)
T2  694.9 N
T1  1764.9 N
Let,
Power P   T1  T2  v
 1764.9  694.9  2.5

P  2.67kW
2.67  2.5
increase inpower   0.07  7%
2.5
Ex. 5.14 In a belt-drive, the mass of the belt is 1 kg/m length and its speed is 6 m/sec. The drive
transmits 9.6 kW of power. Determine the initial tension in the belt and strength of the belt.
The coefficient of friction is 0.25 and the angle of the lap is 220°.
m  1kg / m
v  6 m / sec
P  9.6  103 Watt
T0  ?
Strength  ?
  0.25

  220  rad
180
Let,
Power P   T1  T2  v
9600   T1  T2  6
T1  T2  1600N ______(1)
Let,
T1
2.3log10  
T2
  
 0.25   220  
 180 
T1
  2.31 _____(2)
T2
Solving equation (1) & (2),
T1  2594 N
T2  994 N
Let,

Centrifugal Tension TC  m v2
 1(6)2  36 N
T1  T2 2594  994
Initial Tension T0   TC   36  1830 N
2 2
Strength of the belt  Total Tension on tight side
 T1  TC
 2594  36  2630 N
Ex. 5.15 In an open bet drive, the diameters of the larger and smaller pulley are 1.2 m & 0.8 m
respectively. The smaller pulley rotates at 320 rpm. The centre distance between the
shafts is 4 m. When stationary, the initial tension in the belt is 2.8 kN. The mass of the belt
is 1.8 kg/m and µ = 0.25. Determine the power transmitted.
d1  1.2 m, N1  ?
d2  0.8 m, N2  320 rpm
x 4m
T0  2800 N
m  1.8 kg / m
  0.25
Power  ?
 d2 N2   0.8  320
Velocity of Belt    13.40 m / sec
60 60
Centrifugal Tension TC  m v2
 1.8 (13.4)2  323.4 N
T1  T2
Initial Tension T0   TC
2
T T
2800  1 2  323.4
2
T1  T2  4953N _____(1)
 r  r 0.6  0.4 
 sin   1 2  
Angle of contact   180  2   X 4 
180    2.86 

 180  2 2.86  
180
  3.042rad
Let,
T1
2.3log10  
T2
  0.25  3.042 

T1
  2.14 _____(2)
T2
T1  3376 N
T2  1577 N
Power P   T1  T2  v
  3376  157713.4  24106 Watt  24.10 kW
Ex. 5.16 The initial tension in a belt drive is found to be 600 N and the ratio of friction tension is 1.8.
The mass of the belt is 0.8 kg/m length. Determine:
(i) The velocity of the belt for maximum power transmission
(ii) Tension on the tight side of the belt when it is started
(iii) Tension on the tight side of the belt when running at maximum speed
Solution: (i) Velocity of the belt (v)
Let max power condition for initial tension,
T0 600
v   15.81m / sec
3m 3  0.8
(ii) Tension on tight side when belt is started v = 0, TC = 0
2 k T0 2 1.8  600
T1    771.4 N
k 1 1.8  1
(iii) Tension on the tight side when the belt is running at max speed
2 k  T0  TC 
T1 
k 1
2 1.8  600 199.7

1.8  1 TC  m v2 
T1  514.6 N  
  0.8 15.8   199.7 N
2
Or
T1  T2
T0   TC
2 …………….. with this equation you can solve the problem.
T1  T2
T0   TC
2
 T 
T1   1 
600   1.8   199.7
2
 T1  514.6 N

Ex. 5.17 The driving pulley of an open belt drive is 800 mm diameter and rotates at 320 rpm while
transmitting power to a driven pulley of 250 mm diameter. The Young’s modulus of
elasticity of the belt material is 110 N/mm 2. Determine the speed lost by the driven pulley
due to creep if the stresses in the tight and slack sides of the belt are found to be 0.8
N/mm2 and 0.32 N/mm2 respectively.
OpenBelt Drive
D1  0.8 m, N1  320 rpm
D2  0.250 m
E  110 N / mm2
1  0.8 N / mm2
2  0.32 N / mm2
Let,
N2 D1  E  2 
   ( Velocity Ratio with creep )
N1 D2  E  1 
800  110  0.32 

N2  320     1021rpm
250  110  0.8 
Let velocity ratio without creep,

N2 D1

N1 D2
800
N2  320   1024 rpm
250
Speedlost due to creep  1024  1021  3rpm
Ex. 5.18 The centre to centre distance between two sprockets of a chain drive is 600 mm. The chain
drive is used to reduce the speed from 180 rpm to 90 rpm on the driving sprocket has 18
teeth and a pitch circle diameter of 480 mm. Determine:
(i) No. of teeth on the driven sprocket
(ii) Pitch and the length of chain

C  Centre dis tance between sprocket  600 mm
N1  180 rpm ,T1  18 teeth
N2  90 rpm ,T2  ?
1.
N2 T1 N1
  T2  T1 
N1 T2 N2
180
 18   36 Teeth
90

2. Pitch of the chain (p)
 180  180
p  2R sin    2  0.240  sin  0.04183m  41.83mm
 T  36
3. Length of chain (L)
  180 180 
2

  cosec  cosec 
Tt T t 
L p    2k 
 2 4k 
 
 
  180 180 
2

 cosec  cosec 
 36  18  36 18 
L  0.04183   2  14.343
 2 4  14.343 
 
 
 
C  centre dist. between sprocket 
 
  k p 
 C 0.600 
k    14.343 
 p 0.04183 
Therefore, L  2.351m
References:

Contents
6.1 Introduction ....................................................................................................................................... 6.2

6.2 Screw Threads ................................................................................................................................... 6.8
6.3 Introduction about pivot & collar friction ....................................................................................... 6.12
6.4 Friction clutches .............................................................................................................................. 6.22
6.5 Brakes .............................................................................................................................................. 6.26
6.6 Classification of brakes .................................................................................................................. 6.27
6.7 Braking of Vehicle ........................................................................................................................... 6.36
6.8 Problems .......................................................................................................................................... 6.41
6.1 Introduction
When a body slides over another, the motion is resisted by a force called “Force of Friction”.
 It is impossible to produce a perfectly smooth surface. A block is placed on a surface, the
interlocking of projecting particles takes place due to surface roughness of the surfaces.
 The force of friction on a body is parallel to the sliding surface and acts in a direction opposite to
that of the sliding body.
The case I (To be reduced force of friction)
 In the case of lathe machine, journal bearing, etc. where the power transmitted is reduced due to
friction. It has to be increased by the use of lubricated surfaces.
Case II (To be increased force of friction)
 In the process, where the power is transmitted through friction attempts are made to increase it to
transmit more power. E.g. Friction clutch & Belt drive. Even the toughness of a nut and bolt is
dependent mainly on the force of friction.
6.1.1 Types of Friction
6.1.1.1 Dry Friction

It occurs when there is relative motion between two completely unlubricated surfaces. They are divided
into two types:
(a) Solid Friction: When the two surfaces have a sliding motion relative to each other, it is called
solid friction.
(b) Rolling Friction: Friction due to rolling of one surface over another is called rolling friction. E.g.
ball and roller bearings.
6.1.1.2 Skin or Greasy Friction

When the two surfaces in contact have a minute thin layer of lubricant between them, it is known as skin
or greasy friction. Higher spots on the surface break through the lubricant and come in contact with the
other surface.
6.1.1.3 Film Friction

When the two surfaces in contact are completely separated by a lubricant, friction will occur due to the
shearing of different layers of the lubricant. This is known as film friction or viscous friction.
6.1.2 Laws of Friction

Experiments have shown that the force of solid friction
 is directly proportional to the normal reaction between the two surfaces s opposes the motion
between the surfaces.
 depends upon the materials of the two surfaces.
 is independent of the area of contact.
 is independent of the velocity of sliding.

Unit-6 Friction, Clutch and Brake
6.1.3 Coefficient of Friction and Limiting angle of Friction
Let a body of weight W rests on a smooth and dry plane surface. Under the circumstances, the plane
surface also exerts a reaction force Rn on the body which is normal to the plane surface. If the plane
surface considered is horizontal, R would be equal and opposite to W.
Fig.6.1 - Coefficient of Friction
Let a small horizontal force F be applied to the body to move it on the surface. So long the body is unable
to move, the equilibrium of the body provides,
Rn= W and
F = F’
where F’= Horizontal force resisting the motion of the body. As force F is increased, the relative
force F’ also increased accordingly.
F’ and Rn, the friction and the normal reaction force can be combined into a single reaction force R with
angle θ.
R cosθ = W and
R sinθ= F
At a moment, when the force F would just move the body, the value of F’ or R sinθ (equal to F) is called the
static force of friction. Angle θ attains the value φ and the body is in equilibrium under the action of three
forces as follow:
1. F, in the horizontal direction
2. W, in the vertically downward direction and
3. R, at an angle φ with the normal (inclined towards the force of friction).
Let,
𝐹′ ∝ 𝑅𝑛
where μ = coefficient of friction
= 𝜇𝑅𝑛
F'
 
Rn
In Fig.6.1 (c)
F' R n
tan   
Rn Rn
Hence,
tan   
The angle φ is known as “limiting angle of friction” or simply “angle of friction”.
6.1.4 Angle of Repose
Fig.6.2 - Angle of Repose
When a body is at rest on an inclined plane making an angle α with the horizontal, the forces acting on the
body are:
W, the weight of the body in a downward direction
Rn, normal reaction
F’, the force resisting the motion of the body.
From equilibrium conditions,
W sinα = F’ and W cosα = Rn
If the angle of inclination of the plane is increased, the body will just slide down the plane of its own when
W sinα = F’ = μ Rn
W sinα = μ (W cosα)
tanα = μ = tanφ
This maximum value of angle of inclination of the plane with the horizontal when the body starts sliding
of its own is known as the angle of repose or limiting angle of friction.
6.1.5 Motion up the plane

Consider a body moving up an inclined plane under the action of force F shown in Fig.6.3 (a). As the motion
is up the plane, the friction force F’ = μ R n would act downward along the plane. The body is in equilibrium
under the action of three forces: Weight of body (W), External force (F) and Resultant reaction (R).
Applying Lami's theorem, we get
F W

sin 180        sin 180       
F W

sin      sin        
W sin     
 F
sin        

Fig.6.3 - Motion up the plane
Case 1: If the force applied is horizontal, θ=90°
W sin      W sin     
F   W tan     
sin 90        cos     
Case 2: If the force applied is parallel to the plane, θ=90° + α
W sin     
F
sin        
W sin     

sin  90          
W sin     

sin  90   
W sin     

cos 
W  sin  cos   cos  sin  


cos 
 W  sin   cos  tan  
 W  sin    cos    tan    
Case 3: F will be minimum if the denominator on the right-hand side is maximum,

W sin     
F
sin        
sin          1
        90
   90     
The angle between F and the inclined plane should be equal to the angle of friction. In that case,
Fmin  W sin     
Efficiency: It is defined as the ratio of the forces required to move the body without consideration and with
consideration of the force of friction.   F0 F

Let F0 = force required to move the body up the plane without friction.
In the absence of friction, φ = 0.
W sin     
F0  No friction   0
sin        
W sin 

sin     
F0 F0  Force without friction 

Let   
F F  Force with friction 
W sin 
sin     

W sin     
sin        
W sin  sin        

sin      W sin     
sin  sin  cos       cos  sin     

sin      sin  cos   cos  sin 
 cos      cos  
sin  sin        
sin   sin      sin  

sin       cos  cos  
sin  sin   
 sin  sin  
cot       cot 

cot   cot 
If   90
cot       cot 90

cot   cot 90
cot       cot 90

cot   cot 90
tan 

tan     
6.1.6 Motion down the plane

When the body moves the down plane, the force of friction F’ = μ R n acts in the upward direction and
reaction R (i.e. combination of R= and F’) is inclined.
Assume that F acts downwards. Applying Lami’s theorem Error! Reference source not found. (b),
𝐹 𝑊 Eq. (6.1)
=
sin[𝜋 − (𝜑 − 𝛼)] sin[𝜃 + (𝜑 − 𝛼)]
𝑊sin(𝜑 − 𝛼)
∴ 𝐹 =
sin[𝜃 + (𝜑 − 𝛼)]

Fig.6.4 - Motion down the plane
In Eq. (6.1), F is positive only for φ> α and when φ = α, the force required to slide the body down is zero or
body is on the point of moving down under its own weight W.
When φ<α, i.e. the angle of friction < the angle of the inclined plane, F will be negative meaning that a force
equal to F is to be applied in the opposite direction to resist the motion.
For a given value of α, F is minimum when the denominator of Eq. (6.1) is maximum.
Fmin  W sin     
W sin   
F0  No friction   0
sin     
 W sin 

sin     
Note: The force is negative indicating that in the absence of the force of friction.
Efficiency: It is defined as the ratio of the forces required to move the body with and without the
consideration of force of friction.
F W sin      sin     
 
F0 sin         W sin 
sin      sin  cos   cos  sin 

sin  cos       cos  sin      sin 
 cos  cos  
sin  sin   
sin       sin  sin  

 cos      cos   sin 
sin  sin        
 sin      sin  
cot   cot 

cot       cot 
When θ = 90° or the force applied is horizontal.
cot  tan     
 
cot      tan 

6.2 Screw Threads
A screw thread is obtained when the hypotenuse of a right-angle triangle is wrapped around the
circumference of a cylinder.
Fig.6.5 - Screw Threads
In Fig.6.5, d = diameter of cylinder and l = lead (or p = pitch for single start thread)
Length of base = circumference of the cylinder of screw thread = πd
l p
 tan   
d d
6.2.1 Square Threads

A square-threaded screw used as a jack to raise a load W. Faces of the square threads in the sectional
view is normal to the axis of the spindle. Force F acting horizontally is the force of the screw thread
required to slide the load W up the inclined plane.
W sin     
F (Taken   90)
sin 90       
W sin     

cos     
 W tan     
tan   tan 
W
1  tan  tan 
l
  l 
 tan   
 W d  d 
l  tan    
1 
d
l  d
W
d  l
A bar is usually fixed to the screw head to use as a lever for the application of force.
Let, f = force applied at the end of the bar of length L
Then

d
fL  F  Fr
2
Fr Wr
f  tan     
L L
If weight to be lowered,
W sin     
F (Taken   90)
sin        
W sin     

sin 90       
W sin     

cos     
 W tan     
Fr Wr
f  tan     
L L
6.2.1.1 Screw Efficiency
work done in lifting load / rev


work done by applied load / rev
Wl

F  d
W
 tan 
W tan     
tan 

tan     
d
This is maximum, when 0.
d
d  tan  
  0
d  tan      
sec2  tan       sec2      tan 
0
tan 2     
sec2  tan       sec 2      tan   0
tan      tan 

sec     
2
sec2 
sin      sin 
cos 2       cos 2 
cos      cos 
sin      cos       sin  cos 
2sin      cos       2sin  cos 
sin 2       sin 2

This is possible if        , i.e.   0 (or no friction).
sin 2       sin    2 
2         2
4  2  
  2 
  45 
4 2
Thus, the necessary condition for the maximum efficiency is

  45 
2
tan 
 max 
tan     
 
tan  45  
  2
  
tan  45    
 2 
  1
 tan  45  
 2  
tan  45  
 2
𝜑 𝜑
tan45° − tan 1 − tan45°tan
=( 2 2
𝜑) ( 𝜑)
1 + tan45°tan tan45° + tan
2 2
𝜑 𝜑
(1 − tan ) (1 − tan )
= 2 2
𝜑 𝜑
(1 + tan ) (1 + tan )
2 2
𝜑 2
(1 − tan 2 )
=
𝜑 2
(1 + tan )
2
2
sin 𝜑⁄2
(1 − )
cos 𝜑⁄2
= 2
sin 𝜑⁄2
(1 + )
cos 𝜑⁄2
𝜑 𝜑 2
(cos 2 − sin 2 )
=
𝜑 𝜑 2
(cos + sin )
2 2
𝜑 𝜑 𝜑 𝜑
cos2 + sin2 − 2cos sin
= 2 2 2 2
2 𝜑 2 𝜑 𝜑 𝜑
cos + sin + 2cos sin
2 2 2 2
𝜑 𝜑
1 − 2cos 2 sin 2
= 𝜑 𝜑
1 + 2cos sin
2 2

1 − sin𝜑
∴ 𝜂max =
1 + sin𝜑
weight lifted W W L
 Mechanical advantage     cot     
Wr
force applied f tan     r
L
distance moved by force / rev

Also Velocity ratio 
distance moved by load / rev
2L L L
VR   
l l d r tan 
d 2
6.2.1.2 Overhauling and self-locking screw

We know that the tangential force required to lower the load at the circumference of the screw is F = W
tan(φ-α).
Torque, T = F r = =W tan(φ - α) r
If φ<α, T will be negative. That means the load will start moving down without applying torque. Such a
condition is called “overhauling of the screw”.
If φ> α, T will be positive. That means that some torque is required to lower the load and such a screw is
called “self-locking screw”.
6.2.1.3 The efficiency of self-locking screw
tan 

tan     
tan 
 (For self  locking screw   )
tan     
tan 

tan 2
tan 

 2 tan  
 
 1  tan  
2
1 tan 2 
 
2 2
Note: The efficiency of the self-locking screw is less than 50%. If it is greater than 50% then the screw is
overhauling screw.
6.2.2 V Threads
In the case of V-threads, the faces are inclined to the axis of the spindle even if the helix angle is neglected.
Fig.6.6 shows a section through a V-thread in which 2β is the angle between the faces of the thread (α has
not been considered Thus, not shown).
If Rn, is the normal reaction then clearly the axial component of Rn, must be equal to W, i.e.,

W  R n cos 
W
Rn 
cos 
Fig.6.6 - Screw Threads
Friction force on the surface = μ Rn
W

cos 
   
 W  '  
cos   cos  
  'cos 
6.3 Introduction about pivot & collar friction

It frequently happens that a rotating shaft is subjected to axial thrust. In order to bear this thrust exerted
on the shaft, it is necessary to provide the thrust bearing at shaft end. This bearing not only takes up the
axial thrust but in additional help to preserve the shaft in their correct axial position.
The relative motion between the contact surfaces of a thrust bearing and the shaft is resisted by friction
between their surfaces.
Assumptions:
a) Uniform pressure theory
If the bearings are new and the fit between the shaft and bearing surface is perfect, it is safe to
assume that the load is well distributed over the entire area of contact.
or
The intensity of pressure distributed over the area of contact is constant.
P = constant
b) Uniform wear theory
When the bearings become old, the bearing surface is worn out. The wear of surface at the different
point of contact depends upon the product of the intensity of pressure and velocity of rubbing at
point of contact (PV).
The velocity of rubbing is also different since it depends upon the radius from the axis of rotation
for a given uniform angular speed of the shaft.
So, P V = constant
P r = constant
6.3.1 Types of pivot bearing
Fig.6.7 - Types of pivot bearing
1) Flat pivot bearing

2) Flat collar pivot bearing
3) Conical pivot bearing
4) Trapezoidal or truncated pivot bearing
6.3.1.1 Flat pivot bearing
Fig.6.8 - Flat pivot bearing

Consider a shaft supported in a flat pivot bearing and rotating with uniform velocity ω.
Let, W = Axial load on bearing (N)
R = Radius of the shaft (radius of bearing) (mm)
P = Intensity of pressure per unit area (N/mm2)
μ = Coefficient of friction between the shaft and bearing surface
a) Uniform pressure
Assume the intensity of pressure over the entire bearing surface is constant.
P = constant
Load W
P 
Bearing surface area R 2
Consider an elemental ring of radius r and thickness dr

So the area of the ring,
A  2r dr
Load acting on the ring,
W  pressure  area of ring
W  P 2rdr
Frictional torque on the ring,
Tr  Fr r
  P 2rdr   r
 2 Pr 2 dr
Total torque on the bearing,
R
T   Tr dr
0
R
  2 Pr 2dr
0
R
 r3 
 2 P  
 3 0
R3
 2 P
3
W R3  W 
 2 P  
R 2 3  R 2 
2
T  WR
3

b) Uniform wear
Assuming that wear is uniform over the entire bearing surface, i.e. Pr = constant = C. Hence, P=C/r.
W  P dA
 P  2rdr 
C
  2rdr 
r
W  2Cdr
The total load transmitted,
R
W   2C dr
0
 2C  r 0
R
 W 
W  2CR  C  
 2R 
Frictional torque at the ring,
Tr  2 Pr 2 dr
C 2
 2 r dr
r
 2Crdr
Total torque,
R
T   Tr dr
0
R
  2Crdr
0
R
 r2 
 2C  
 2 0
W R2
 2
2R 2
1
T  WR
2
6.3.1.2 Flat collar bearing

Consider a shaft supported in a flat collar bearing.
Let, W = Total axial load on bearing
R1 = External radius of collar
R2 = Internal radius of collar

P = Intensity of pressure per unit area
Fig.6.9 - Flat collar bearing
a) Uniform pressure
The pressure is uniformly distributed over the bearing surface area.
Load W
P 

Area  R12  R 22 
For flat pivot bearing torque on the ring,
Tr  2 Pr 2 dr
Total torque,
R1
T  Tr dr
R2
R1
  2 Pr
2
dr
R2
R
 r3  1
 2P   P  constant
 3 R2
R13  R 32
 2P
3
W R13  R 32
 2

 R12  R 22  3
2 R13  R 32
T  W 2
3 R1  R 22

b) Uniform wear
Assuming that wear is uniform over the entire bearing surface, i.e. Pr = constant = C. Hence P=C/r.
W  P dA
 P  2rdr 
C
 2rdr 
r
W  2Cdr
R1
W  2C dr
R2
 2C  r R1
R
2
 W 
W  2C  R1  R 2   C  
 2  R1  R 2  
We know that for flat pivot bearing, Tr  2Crdr
Total torque,
R1
T  Tr dr
R2
R1
  2Crdr
R2
R
 r2  1
 2C  
 2 R2
 2
W 
R12  R 22 
2  R 1  R 2  2
1
T  W  R1  R 2 
2
Fig.6.10 - Multiple flat collar bearing

For multiple flat collar bearing,
Load Load W
P  

Area no. of collar  bearing surface area n  R12  R 22 
6.3.1.3 Conical pivot bearing
Fig.6.11 – Conical pivot bearing
Consider a shaft supported in a conical pivot bearing.

R = Radius of the collar
Pn = Intensity of pressure normal to the cone
Α = Semi angle of the cone
Consider a small ring of radius r and thickness dr.
Length of the ring,
l  dr cosec
Area of the ring,
A  2r l
 2r dr cosec
a) Uniform pressure
Normal load acting on the ring,
Wn  normal pressure  area

 Pn 2rdr cosec

Vertical load acting on the ring,
W  vertical component of Pn  area

 Pn sin  2rdr cosec
 Pn 2rdr
R
W   W
0
R
  Pn 2r dr
0
R
 r2 
 2Pn  
 2 0
R2
 2Pn
2
 W 
W  R 2 Pn Pn  i.e. pressure is uniformly distributed 
 R 2

Frictional resistance at radius r,
Fr   Wn
  Pn 2rdr cosec 2 Pn cosec rdr
Frictional torque,
Tr  Fr r
 (2 Pn cosec rdr) r

 2 Pn cosec r 2dr
Total frictional torque,
R
T   2 Pn cosec r 2dr
0
R
 r3 
 2 Pn cosec  
 3 0
W R3
 2 cosec
R 2 3
2
T  WR cosec
3
b) Uniform wear
Assuming that wear is uniform over the entire bearing surface, i.e. Pn r = constant = C. So Pn = C/r.
Vertical load on the ring,
W  Pn 2rr
C
 2rdr
r
 2Cdr

R
W   2Cdr
0
 2C  r 0
R
 W 
W  2CR  C  
 2R 
We know that frictional torque on the ring,
Tr  2 Pn cosec r 2dr

C
 2 cosec r 2dr
r
 2 C cosec rdr
Total frictional torque T,
R
T   Tr dr
0
R
  2 C cosec rdr
0
R
 r2 
 2 C cosec  
 2 0
W R2
 2 cosec
2R 2
1
T  WR cosec
2
6.3.1.4 Trapezoidal or truncated conical pivot bearing

R1 = External radius of collar
R2 = Internal radius of collar
Pn = Intensity of pressure normal to the cone
2α= Angle of cone
a) Uniform pressure
The pressure is uniformly distributed over the bearing surface area.

Load W
P 

Area  R1  R 22
2

Fig.6.12 - Trapezoidal or truncated conical pivot bearing
Consider a small ring of radius r, thickness dr and truncated length dl. We have derived the equation for
frictional conical pivot bearing torque,
Tr  2 Pn cosec r 2dr
Total frictional torque,

R1
T  2 Pn cosec r dr
2
R2
R
 r3  1
 2 Pn cosec  
 3 R2
 2
W
cosec
R 3
1  R 32 
  R12  R 22  3
2
T  W
R 3
1  R 32  cosec
3 R 2
1  R 22 
b) Uniform wear
Assuming that wear is uniform over the entire bearing surface, i.e. Pn r = constant = C. So Pn=C/r.
Vertical load on the ring,
W  Pn 2rr
C
 2rdr
r
 2Cdr

R1
W  2Cdr
R2
 2C  r R 2
R
1
 W 
W  2C  R1  R 2   C  
 2  R1  R 2  
As we know that frictional torque on the ring,
Tr  2 Ccosec rdr

Total frictional torque T,
R1
T  2 C cosec rdr
R2
R
 r2  1
 2 C cosec  
 2 R2
 2
W
cosec

R12  R 22 
2  R1  R 2  2
1
T  W  R1  R 2  cosec
2
6.4 Friction clutches

A clutch is a device used to transmit the rotary motion of one shaft to another when desired. The axes of
the two shafts are coincident.
6.4.1 Disc clutch

A disc clutch consists of a clutch plate attached to a splined hub that is free to slide axially on splines cut
on the driven shaft. The clutch plate is made of steel and has a ring of friction lining on each side. The
engine shaft supports a rigidly fixed flywheel.
A spring-loaded pressure plate presses the clutch plate firmly against the flywheel when the clutch is
engaged.
When disengaged, the springs press against a cover attached to the flywheel. Thus, both the flywheel and
the pressure plate rotate with the input shaft. The movement of the clutch pedal is transferred to the
pressure plate through a thrust bearing.
Fig.6.13 shows the pressure plate pulled back by the release levers and the friction linings on the clutch
plate are no longer in contact with the pressure plate or the flywheel. The flywheel rotates without driving
the clutch plate and thus, the driven shaft.
When the foot is taken off the clutch pedal, the pressure on the thrust bearing is released. As a result, the
springs become free to move the pressure plate to bring it in contact with the clutch plate. The clutch plate
slides on the splined hub and is tightly gripped between the pressure plate and the flywheel. The friction

between the linings on the clutch plate, and the flywheel on one side and the pressure plate on the other,
cause the clutch plate and hence, the driven shaft to rotate.
Fig.6.13 - Disc clutch
6.4.2 Multi-plate clutch

In a multi-plate clutch, the number of frictional linings and the metal plates is increased which increases
the capacity of the clutch to transmit torque. Fig.6.14 shows a simplified diagram of a multi-plate clutch.
Fig.6.14 - Multi-plate clutch
The friction rings are splined on their outer circumference and engage with corresponding splines on the
flywheel. They are free to slide axially. The friction material thus rotates with the flywheel and the engine
shaft. The number of friction rings depends upon the torque to be transmitted.
The driven shaft also supports discs on the splines which rotate with the driven shaft and can slide axially.
If the actuating force on the pedal is removed, a spring presses the discs into contact with the friction
rings and the torque is transmitted between the engine shaft and the driven shaft.
If n is the total number of plates both on the driving and the driven members, the number of active surfaces
will be n – 1.

6.4.3 Cone clutch
In a cone clutch (Fig.6.15), the contact surfaces are in the form of cones. In the engaged position, the
friction surfaces of the two cones A and B are in complete contact due to spring pressure that keeps one
cone pressed against the other all the time.
Fig.6.15 - Cone clutch
When the clutch is engaged, the torque is transmitted from the driving shaft to the driven shaft through
the flywheel and the friction cones. For disengaging the clutch, the cone B is pulled back through a lever
system against the force of the spring. The advantage of a cone clutch is that the normal force on the
contact surfaces is increased.
If F= Axial force
Fn= Normal force
α= Semi angle of the cone
Applying uniform wear theory,
𝐹 Eq. (6.2)
𝐹𝑛 =
sin𝛼
Ro
Axial force, F  Axial force on elemetnt area
Ri
Ro
  Pressure on element  Area
Ri
Ro
  P 2r dr
Ri
Pr  C 
Ro
C
  r
2r dr  
  Constant 
Ri
Ro
  2C dr
Ri
 2C  r R o
R
i
 2 Pr  R o  R i 

The intensity of pressure P at radius r of the collar,
F
P
2r  R o  R i 
Putting in Eq. (6.9),
F
Fn 
sin 
2 Pr  R o  R i 
 R  Ri  
sin   o 
  b 
sin  b  width of cone face 
 
Fn  2 Prb
Let,
1 R  Ri   1 
T  F o T  W  R o  R i  cosec 
2 sin   2 
Here R m  Mean radius 
Fn sin   R o  R i   

sin  2


 Ro  Ri  
 
 2 
T  Fn R m
However, cone clutches have become obsolete as small cone angles and exposure to dust and dirt tend
to bind the two cones and it becomes difficult to disengage them.
6.4.4 Centrifugal clutch
Fig.6.16 - Centrifugal clutch
Centrifugal clutches are being increasingly used in automobiles and machines. A centrifugal clutch has a
driving member consisting of four sliding blocks (Fig.6.16).

These blocks are kept in position by means of flat springs provided for the purpose. As the speed of the
shaft increases, the centrifugal force on the shoe increases.
When the centrifugal force exceeds the resisting force of the springs, the shoes move forward and press
against the inside of the rim and thus, torque is transmitted to the rim.
In this way, the clutch is engaged only when the motor gains sufficient speed to take up the load in an
effective manner. The outer surfaces of the shoes are lined with some friction material.
Let, m = mass of each shoe
R = inner radius of the pulley rim
r = distance of the center of mass of each shoe from the shaft axis
n = number of shoes
𝜔= normal speed of the shaft in rad/s
𝜔’ = speed at which the shoe moves forward
𝜇= coefficient of friction between the shoe and the rim.
The centrifugal force exerted by each shoe at the time of engagement with the rim = mr ' = resisting
2
force of the spring.

2
The centrifugal force exerted by each shoe at normal speed = mr
= mr  mr '

2 2
Net normal force exerted by each shoe on the rim

= mr 2   '2 
The frictional force acting tangentially on each shoe 
=  mr 2   '2 
Frictional torque acting on each shoe 
=  mr 2   '2 R 
Total frictional torque acting 
=  mr 2   '2 R n 
If p is the maximum pressure intensity exerted on the shoe, then
l  Length of shoe 
 
mr 2   '2  p lb 
b  Width of shoe 

Note: Usually, the clearance between the shoe and the rim is very small and is neglected.
6.5 Brakes
A brake is defined as a mechanical device that is used to absorb the energy possessed by a moving system
or mechanism by the friction. The primary purpose of the brake is to slow down or completely stop the
motion of moving systems such as rotating drums, machines or vehicles. It is also used to hold the parts
of the system in position at rest.
An automobile brake is used either to reduce the speed of the car or bring it to rest. It also used to keep
the car stationary on the downhill road. The energy absorbed by the brake can be either kinetic or potential
or both. In automobile applications, the brake absorbs the kinetic energy of moving vehicles.

In hoists and elevators, the brake absorbs the potential energy released by the object during the braking
period. The energy absorbs by the brake converts into heat energy and dissipated to the surrounding. Heat
dissipation is a serious problem in brake application.
6.6 Classification of brakes

Brakes are classified into the following three groups:
(a) Mechanical brakes are operated by mechanical means such as levers, springs, and pedals.
Depending upon the shape of the friction material, the mechanical brakes are classified as Block
brakes, Band Brakes, Block and Band Brake and internal or external shoe brakes.
(b) Hydraulic brakes and pneumatic brakes which are operated by fluid pressure such as oil pressure
or air pressure.
(c) Electrical brakes are operated by magnetic force and which include magnetic particle brakes,
hysteresis brakes, and eddy current brakes.
Brake capacity depends upon the following factor.
 The unit pressure between the braking surface.
 The contacting area of the braking surface.
 The radius of the brake drum
 The coefficient of friction
 The ability of the brakes to dissipate heat that is equivalent to the energy being absorbed.
6.6.1 Energy Equations

The first step in the design of a mechanical brake is to determine the braking-torque capacity for the given
application. The braking-torque depends upon the amount of energy absorbed by the brake. When a
mechanical system of mass m moving with a velocity v1 is slowed down to the velocity v2during the period
of braking, the kinetic energy absorbed by the brake is given by
KE  m  v12  v 2 2 
1
2
Where KE = kinetic energy absorbed by the brake (J)
m = mass of the system (kg)
v1 and v2 = initial and final velocities of the system (m/s)
Similarly, the kinetic energy of the rotating body is given by
KE  I  12  2 2 
1
2
KE  mk 2  12  2 2 
1
2
where I =mass moment of inertia of the rotating body (kg-m2)
k = radius of gyration of the body (m)
ω1, ω2 = initial and final angular velocities of the body (rad/s)

In certain applications like hoists, the brake absorbs the potential energy released by the moving weight
during the braking period. When a body of mass m falls through a distance h, the potential energy absorbed
by the brake during the braking period is given by
PE =mgh
where, g =gravitational constant (9.81 m/s2)
Depending upon the type of application, the total energy absorbed by the brake is determined by adding
the respective quantities of energy discussed above. This energy is equated to the work done by the brake.
Therefore,
E = Tb θ
where E = total energy absorbed by the brake (J)
Tb = braking torque (N-m)
θ = angle through which the brake drum rotates during the braking period (rad)
6.6.2 Block or Shoe Brake
Fig.6.17 - Block or Shoe Brake

A block or shoe brake consists of a block or shoe which is pressed against a rotating drum. The force on
the drum is increased by using a lever [Fig.6.17 (a)].
If only one block is used for the purpose, aside from thrust on the bearing of the shaft supporting the drum
will act. This can be prevented by using two blocks on the two sides of the drum [Fig.6.17 (b)]. This also
doubles the braking torque.
A material softer than that of the drum or the rim of the wheel is used to make the blocks so that these
can be replaced easily on wearing. Wood and rubber are used for light and slow vehicles and cast steel
for heavy and fast ones.

Let,
r  Radius of drum
  Co  efficient of friction
Fr  Radial force applied on the drum
Rn  Normalreaction on the block
F  Force applied at the lever end
Ff  Frictional force  Rn
Assuming that normal reaction Rn and frictional force Ff act at the midpoint of the block.
Breaking Torque  Frictional force  Radius

 Rn  r
The direction of the frictional force on the drum is to be opposite to that of its rotation while on the block
it is in the same direction. Taking moments about the pivot O [Fig. 2.10(a)],
F × a − R n × b + μR n × c = 0
F⋅a
Rn =
b − μc
b − μc
F = R n ⋅
a
When b  c , F = 0 which implies that the force needed to apply the brake is virtually zero, or that once
contact is made between the block and the drum, the brake is applied itself. Such a brake is known as a
self – locking brake.
As the moment of the force Ff about O is in the same direction as that of the applied force F, Ff aids in
applying the brake. Such a brake is known as a self – energized brake.
If the rotation of the drum is reversed, i.e., it is made clockwise,
F  Rn b  c  / a
which shows that the required force F will be far greater than what it would be when the drum rotates
counterclockwise.
a
If the pivot lies on the line of action of Ef, i.e., at O’, c = 0 and F  Rn ,
b
which is valid for clockwise as well as for counterclockwise rotation.
If c is made negative, i.e., if the pivot is at O’’,
 b  c 
F  Rn   for counter  clockwise rotation
 a 
and
 b  c 
F  Rn   for clockwise rotation
 a 
In case the pivot is provided on the same side of the applied force and the block as shown in Fig.6.17 (c),
the equilibrium condition can be considered accordingly.
In the above treatment, it is assumed that the normal reaction and the frictional force act at the midpoint
of the block. However, this is true only for small angles of contact. When the angles of contact are more
than 40°, the normal pressure is less at the ends than at the center.
In that case, µ has to be replaced by an equivalent coefficient of friction µ’ given by
 
 4 sin  2  
'     
   sin 
 
 
6.6.3 Band Brake
Fig.6.18 - Band Brake

It consists of a rope, belt or flexible steel band (lined with friction material) which is pressed against the
external surface of a cylindrical drum when the brake is applied. The force is applied at the free end of a
lever (Fig.6.18).
Brake torque on the drum = ( T1 – T2) r
where r is the effective radius of the drum.

The ratio of the tight and slack side tensions is given by T1 / T2  e on the assumption that the band is on
the point of slipping on the drum.
The effectiveness of the force F depends upon the
 the direction of rotation of the drum
 the ratio of length a and b
 the direction of the applied force F.

To apply the brake to the rotating drum, the band has to be tightened on the drum. This is possible if
1. F is applied in the downward direction when a>b
2. F is applied in the upward direction when a<b
If the force applied is not as above, the band is further loosened on the drum which means no braking
effect is possible.
6.6.3.1 a > b, F Downwards

(a) Rotation Counter – Clockwise
For counterclockwise rotation of the drum, the tight and the slack sides of the band will be as shown
in Fig.6.18. Considering the forces acting on the lever and taking moments about the pivot,
F l – T1 a + T 2 b = 0
𝑇1 𝑎 − 𝑇2 𝑏
∴ 𝐹=
𝑙
As T1> T2 and a> b under all conditions, the effectiveness of the brake will depend upon the force F.
(b) Rotation Clockwise
Fig.6.19 - Rotation Clockwise
In this case, the tight and the slack sides are reversed as shown in Fig.6.19.
Now,
F l – T2 a + T 1 b = 0
𝑇2 𝑎 − 𝑇1 𝑏
∴ 𝐹=
𝑙
As T2< T1 and a> b, the brake will be effective as long as T 2. a is greater than T1. b
T2 b
T2 a  T1 b or 
Or T1 a
i.e., as long as the ratio of T2 to T1 is greater than the ratio b/a.
T2 a

When 1 b F is zero or negative, i.e., the brake becomes self – locking as no force is needed to
T
apply the brake. Once the brake has been engaged, no further force is required to stop the rotation
of the drum.
6.6.3.2 a < b, F upwards
Fig.6.20 - a < b, F upwards

(a) Rotation Counter – Clockwise
The tight and the slack sides will be as shown in Fig.6.20 (a).
Therefore,

F  l  T1 a  T2 b  0
or
T2 b  T1 a
F
l
As T2< T1 and b > a the brake is operative only as long as
T2 a
T2 b  T1 a or 
T1 b
Once T2 / T1 becomes equal to a/b, F required is zero and the brake becomes self – locking.
(b) Rotation Clockwise
The tight and slack sides are shown in Fig.6.20 (b).
From Fig.6.20 (b),
T1 b  T2a
F  l  T1 b  T2 a  0 or F 
l
As T1> T2 and b> a, under all conditions, the effectiveness of the brake will depend upon the force F.
When a = b, the band cannot be tightened and thus, the brake cannot be applied.
Fig.6.21 b = 0 and F downwards

The band brake just discussed is known as a differential band brake. However, if either a or b is made
zero, a simple band brake is obtained. If b = 0 (Fig.6.21) and F downwards,
F  l  T1 a  0
or
a
F  T1
l
Similarly, the force can be found in other cases.
 Note that such a brake can neither have self – energizing properties nor it can be self – locked.
The brake is said to be more effective when maximum braking force is applied with the least effort F.
For case (i), when a > b and F are downwards, the force (effort) F required is less when the rotation is
clockwise assuming that the brake is effective.
For case (ii), when a < b and F are upwards, F required is less when the rotation is counterclockwise
assuming that the brake is effective.
Thus, for the given arrangement of the differential brake, it is more effective when
(a) a > b, F downwards, rotation clockwise
(b) a > b, F upwards, rotation counterclockwise.
The advantages of self – locking is taken in hoists and conveyers where motion is permissible in only one
direction. If the motion gets reversed somehow, the self – locking is engaged which can be released only
by reversing the applied force.
It is seen that a differential band brake is more effective only in one direction of rotation of the drum.
Fig.6.22 – Two-way band brake

However, a two-way band brake can also be designed which is equally effective for both the directions of
rotation of the drum (Fig.6.22). In such a brake, the two lever arms are made equal.
For both directions of rotation of the drum,
F  l  T1 a  T2 a  0
or

F  T1  T2  al
Band brake offers the following advantages:
(i) Band brake has a simple construction. It has a small number of parts. These features reduce the
cost of a band brake.
(ii) Most equipment manufacturers can easily produce band brake without requiring specialized
facilities like a foundry or forging shop. The friction lining is the only part that must be purchased
from outside agencies.
(iii) A band brake is more reliable due to the small number of parts.
(iv) Band brake requires little maintenance.
The disadvantages of band brake are as follows:

(i) The heat dissipation capacity of a band brake is poor.
(ii) The wear of friction lining is uneven from one end to the other.
Band brakes are used in applications like bucket conveyors, hoists and chain saws. They are more popular
as back-stop devices.

6.6.3.3 Band and Block Brake
Fig.6.23 - Band and Block Brake

A band and block brake consists of a number of wooden blocks secured inside a flexible steel band. When
the brake is applied, the blocks are pressed against the drum.
Two sides of the band become tight and slack as usual. Wooden blocks have a higher coefficient of
friction. Thus, increasing the effectiveness of the brake. Also, such blocks can be easily replaced on being
worn out [Fig.6.23 (a)].
Each block subtends a small angle of 2θ at the center of the drum. The frictional force on the blocks acts
in the direction of rotation of the drum. For n blocks on the brake,
Let,
T0  Tension on the slack side.

T1  Tension on the tight side after one block.
T2  Tension on the tight side after two blocks.
Tn  Tension on the tight side after nblocks.

  Coefficient of friction.
Rn  Normalreaction on the block.
Resolving the forces horizontally and vertically
(T1 − T0 )cosθ = μ R n
(T1 + T0 )sinθ = R n
T1 − T0 cosθ μ R n
∴ =
T1 + T0 sinθ Rn

T
1  T0  
 tan 
T1  T0 1

T  T   T  T 
1 0 1 0

 tan   1
T  T   T  T 
1 0 1 0
 tan   1

2T1 1   tan 
 
2T0 1   tan 
T1 1   tan 

T0 1   tan 
Similarly,
T2 1   tan 
 and so on
T1 1   tan 
Tn 1   tan 

Tn1 1   tan 
Tn Tn Tn1 T2 T1
  
T0 Tn1 Tn2 T1 T0
n
 1   tan  
 
 1   tan  
6.6.3.4 Internal Expanding Brake
Fig.6.24 - Internal Expanding Brake

The construction of an internal expanding brake is shown in Fig.6.24. It consists of a shoe, which is pivoted
at one end and subjected to an actuating force P at the other end. A friction lining is fixed on the shoe and
the complete assembly of shoe lining and pivot is placed inside the brake drum.
Internal shoe brakes, with two symmetrical shoes, are used on all automobile vehicles. The actuating force
is usually provided by means of a hydraulic cylinder or a cam mechanism. The analysis of the internal shoe
brake is based on the following assumptions:
 The intensity of normal pressure between the friction lining and the brake drum at any point is
proportional to its vertical distance from the pivot.
 The brake drum and the shoe are rigid.
 The centrifugal force acting on the shoe is negligible.
 The coefficient of friction is constant.

6.7 Braking of Vehicle
Fig.6.25 - A vehicle moving up an inclined plane
In a four-wheeled moving vehicle, the brakes may be applied to

1. The rear wheels only,
2. The front wheels only, and
3. All the four wheels.
In all the above mentioned three types of braking, it is required to determine the retardation of the vehicle
when brakes are applied. Since the vehicle retards, therefore it is a problem of dynamics. But it may be
reduced to an equivalent problem of statics by including the inertia force in the system of forces actually
applied to the vehicle. The inertia force is equal and opposite to the braking force causing retardation.
Consider a vehicle moving up an inclined plane shown in Fig.6.25.
Let,
  Angle of inclination of the plane to the horizontal.
m  mass of vehicle (Such that its weight mg inNewton).
h  Height of C.G. of the vehicle above the road surface (mtr).
x  Perpendicular dis tance of C.G. from the rear axle (mtr).
L  Dis tan ce between centre of rear and front wheel (wheelBase)(mtr).
RA , RB  Reactions of the ground on the front & rear wheel (N).
  Coefficient of frictionbetween tyre androad surface.
a  Retardation of the vehicle (m / s2 ).
6.7.1 Brakes applied to Rear wheel only

It is a common way of braking a vehicle in which the braking force acts at the rear wheel.
Resolving the forces,
FB + m g Sin α = m a Eq. (6.3)
R A + R B = m g Sinα Eq. (6.4)
 FB  Totalbreaking force acting at 

 
 the rear wheel due to application of brakes 
   RB 
 

Taking moment about G,
FB  h  RB  x  RA L  x   FB   RB 
 
 RB  h  RB  x  (m g cos   RB ) L  x   RA  m g cos   RB 
RB   h  x   m g cos  L  x   RB L  x 
RB   h  x  L  x   m g cos  L  x 
m g cos  L  x 
 RB 
L  h
and
RA  m g cos   RB
m g cos  L  x 
 m g cos  
L  h
m g cos   x   h 
RA 
L  h
From Eq. (6.3)
FB  m g sin  m
FB  m g sin 
a 
m
FB
  g sin 
m
 RB
a   g sin  Putting value of RB in equation 
m
 m g cos  (L  x) 
 
 L  h   g sin 
a  
m
 g cos  (L  x)
a   g sin 
L  h
Notes: (1) On Road level α = 0, therefore,
 g (L  x)
a 
L h
(2) When a vehicle moves down a plane, Eq. (6.3) becomes FB  m g sin  ma
FB
a   g sin 
m
 RB
  g sin 
m
 g cos  (L  x)
a   g sin 
L h

6.7.2 Brake applied to Front wheels only
It is a very rare way of braking the vehicle, in which the braking force acts at the front wheels only.
Let,
FA  Braking force acting at the front wheel.

  RA
Resolving the forces horizontally and vertically,

FA + m g Sin α = m a Eq. (6.5)
R A + R B = m g Cosα Eq. (6.6)
Taking moments about G,
 FA   RA 
 
FA  h  RB  x  RA (L  x )  RB  m g cos   RA 
 Putting values.... 
 
 RA  h  m g cos   R A  x  R A L  x 
 RA  h  mg cos   x  RA  L
RA L  h   m g cos   x
m g cos   x
RA 
L  h
Eq. (6.9)
RA  RB  m g cos 
RB  m g cos   R A
m g cos   x
 m g cos  
L  h
 x 
 m g cos  1  
 L  h 
 L  h  x 
RB  m g cos   
 L  h 
Eq. (6.5)
FA  m g sin  ma
FA  m g sin 
a
m
RA  m g sin 
  Putting Value of RA 
m
 m g cos   x 
  m g sin 
 L  h 

m

 g cos   x
a  g sin 
L  h
Notes: (1) On a Road level α = 0,
m g cos   x m g x
RA 
L  h

L  h
cos 0  1
 L  h  x  m g L  h  x 
RB  m g cos    
 L  h  L  h
 g cos   x  
a  g sin   cos 0  1 
L  h  sin 0  0 
 gx

L  h
(2) When a vehicle moves down the plane,
FA  m g sin  ma
FA m g sin 
a 
m m
RA
  g sin 
m
 g cos   x
  g sin 
L  h
6.7.3 Brakes applied to all four wheels

This is the most common way of braking the vehicle, in which the braking force acts on both the rear and
front wheels.
FA  Braking force for front wheels   R A

FB  Braking force for rear wheels   RB
Note: A little consideration will show that when the brakes are applied to all the four wheels, the braking
distance (i.e. the distance in which the vehicle is brought to rest after applying the brakes) will be the least.
It is due to this reason that the brakes are applied to all the four wheels.
Resolving the forces,
FA + FB + m g Sin α = m a Eq. (6.7)
R A + R B = m g Cosα Eq. (6.8)
Taking moment about G,

(FA + FB ) h + R B ∙ x = R A (L − x) Eq. (6.9)
 FA   RA 
 FB   RB 
 
 
 RB  m g cos   RA 
 Putting values in eq.(6.9)
 RA  RB  h  m g cos   R A  x  R A ( L  x )

 RA  m g cos   R A  h  m g cos   R A  x  R A ( L  x )
m g cos   h  x 
RA 
L
RB  m g cos   R A
 h  x 
 m g cos   m g cos   
 L 
 L  h  x 
 m g cos   
 L 
Eq. (6.7)
FA  FB  m g sin  ma
 RA  RB   m g sin   m a
 m g cos   m g sin   m a  RA  RB  m g cos  
a  g   cos   sin  
Notes: (1) On a Road level α = 0,
m g cos   h  x  mg  h  x 
RA  
L L
 L  h  x 
RB  m g  
 L 
ag 
(2) If the vehicle moves down the plane, then it may be written as,
FA  FB  m g sin  ma
 RA  RB   m g sin   m a
 m g cos   m g sin   m a  RA  RB  m g cos  
a  g   cos   sin  

6.8 Problems
Ex. 6.1 The force required just to move a body on a rough horizontal surface by pulling is 320 N
inclined at 30° and by pushing 380 N at the same angle. Find the weight of the body and
the coefficient of friction.
Solution:
(a) Consider the pull Fig. (a)
Resolve forces horizontally F'  320cos30
277
R n  277 Rn  (1)

Resolve forces horizontally R n  320sin30  W
277 277
 160  W   (2)
 W  160
(b) Consider the push Fig. (b)
Resolve forces horizontally F'  380cos30
329
R n  329 Rn  (3)

Resolve forces horizontally R n  W  380sin30
329 329
 W  190   (4)
 W  190
Comparing equations (3) & (4),
277 329
  W  2024.4 N
W  160 W  190
   0.1486
Ex. 6.2 A body is to be moved up an inclined plane by applying a force parallel to the plane surface.
It is found that a force of 3 KN is required to just move it up the plane when the angle of
inclination is 10° whereas the force needed increase to 4 KN when the angle of inclination
is increased to 15°. Determine the weight of the body and the coefficient of friction.
Solution: When the force applied is parallel to the plane surface,
F  W  sin    cos  
3000  W  sin10   cos10  (1)
& 4000  W  sin15   cos15  (2)
Dividing equation (2) by (1),
4000 W  sin15   cos15 

 
3000 W  sin10   cos10 
 sin10   cos10  0.75  sin15   cos15 
   cos10  0.75cos15   0.75sin15  sin10
 0.2604   0.0205
  0.0786 and W  11.95 kN
Ex. 6.3 A square threaded bolt with a core diameter of 25 mm and a pitch of 10 mm is tightened
by screwing a nut. The mean diameter of the bearing surface of the nut is 60 mm. The
coefficient of friction for the nut and the bolt is 0.12 and for the nut and the bearing surface,
it is 0.15. Determine the force required at the end of a 400 mm long spanner if the load on
the bolt is 12 KN.
Solution: Given data:
dc = 25 mm, p = 10 mm, μ = 0.12, μ1= 0.16, l = 400 mm, W = 12 X 103 N
To be Calculated:
F (force required)
p p 10
Let d(mean dia .)  d c  Also tan     0.1061
2 d  30
10
 25   30mm   6.05
2
&   tan      tan 1  0.12   6.84
Let torque T1  F  r Force is applied horizontally

 W tan      r
30
 12000 tan  6.05  6.84 
2
 41192.44 N.mm
Total torque T  T1  T2
d
 F   1WR
2
 41192.44  0.16  12  103  30
 98792.44 N.mm
Now Torque T  Force  Distance

98792.44  F'  400
F'  246.98 N
Ex. 6.4 The cutting speed of a broaching machine is 9 m per minute. The cutter of the machine is
pulled by a square threaded screw with a notational diameter of 60 mm and a pitch 12 mm.
The operating nut takes an axial load of 500 N on a flat surface of 80 mm external diameter
and 48 mm internal diameter. Determine the power required to rotate the operating nut.
Take µ = 0.14 for all contact surfaces on the nut.
do = 60 mm, p = 12 mm, W = 500 N, R1= 80/2= 40 mm, R2 = 48/2= 24 mm, μ = tan φ = 0.14,
μ1= 0.14, l = 400 mm,
To be Calculated:
P (power required)
p p 12
Let d(mean dia .)  d o  Also tan     0.0707
2 d  54
12
 60   54mm   4.046
2
&   tan      tan 1  0.14   7.97
Let force F  W tan     

 500 tan  4.046  7.97 
 106.42 N
d  R  R2 
 F   1W  1 
2  2 
54  40  24 
 106.42   0.14  500   
2  2 
T  5113.34 N.mm  5.11 N.m
Cutting speed 9 m / min

Speed    750 rpm
Pitch 0.012 m
2NT 2 750  5.11

Power P  
60 60
P  401.33 W
Ex. 6.5 The railway coaches with the help of two tie rods of a turnbuckle with right and left-handed
threads having single start square threads. The pitch and mean diameter of the thread are
8 mm and 30 mm respectively. What will be the work done in bringing the two coaches
closer through a distance of 160 mm against a steady load of 2 KN? Take µ =0.12.
Solution:
Given data:
p = 8 mm, d = 30 mm, μ = 0.12, W = 2000 N
To be Calculated:

W (work done)
p 8
tan     0.0848   4.85 &   tan      tan 1  0.12   6.84
d  30
Torque on each rod T  F  r
 W tan      r
30
 2000 tan  4.85  6.84 
2
 6207.24 N.mm
 6.20 N.m
Total torque on coupling nut  2  T  2  6.20  12.4 N.m
In one complete revolution of the road, each coach will move through a distance equal to
pitch.
Number of turns required to move the coaches through a distance by 160 mm,
 160  2  p   160  2  8   10
Work done W  T.

 12.4  210
W  780.4 N.m
tan  tan 4.85

Efficiency   
tan      tan  4.85  6.84 
 0.41
  41
Ex. 6.6 A Whitworth bolt with an angle of V-threads as 55° has a pitch of 6 mm and a mean
diameter of 32 mm. the mean radius of the bearing surface where the nut is tightened is
20 mm. Determine the force required at the end of a 400 mm long spanner when the load
on the bolt is 8 KN. The coefficient of friction for the nut and the bolt is 0.1 and for the nut
and the bearing surface is 0.15.
V-threads, 2β = 55°, p = 6 mm, d = 32 mm, R = 20 mm, W = 8 X 103N, μ = 0.1 = tan φ, μ1= 0.15
To be Calculated:
F’ (force required at the end of a 400 mm long spanner)
 0.1 p 6
'    0.113 & tan     0.0707   3.42
cos  cos 27.5 d  32
Also  '  tan      tan 1  0.113  6.48

 8 103 tan  3.42  6.45 
 1391.90 N

d
 F   1WR
2
32
 1391.90   0.15  8 103  20
2
T  46270.4 N.mm
Let Torque T  Force  Length

46270.4  F'  400
F'  115.67 N
Ex. 6.7 A load of 15 KN is raised by means of a screw jack. The mean diameter of the square
threaded screw is 42 mm and the pitch is 10 mm. A force of 120 N is applied at the end of
a lever to raise the load. Determine the length of the lever to be used and the mechanical
advantage obtained. Is the screw self-locking? Take µ=0.12.
W = 15 X 103 N, d = 42 mm, p = 10 mm ,F = 120 N, μ = 0.12 = tan φ
To be Calculated:
l & MA (length of the lever to be used and the mechanical advantage)
p 10
tan     0.0758   4.335 &   tan      tan 1  0.12   6.843
d  42
Let torque T  F  r
 W tan      r
42
 15 103 tan  4.335  6.843
2
 62245.99 N.mm
Let Torque T  Force  Length
62245.99  120  l
l  518.7 mm
W 15 103
Mechanical Advatage (MA)  
F 120
MA  125
tan  tan 4.335

Efficiency   
tan      tan  4.335  6.843
 0.3836
 38.36  50
So screw is self-locking.
Ex. 6.8 The following data relate to a screw jack:
Pitch of the threaded screw =8 mm
The diameter of the threaded screw =40 mm

Coefficient of friction between screw and nut =0.1
Load =20 KN
Assuming that the load rotates with the screw, determine the
i. The ratio of torque required to raise and lower the load.
ii. The efficiency of the machine.

p = 8 mm, d = 40 mm, μ = 0.1 = tan φ, W = 20 X 103 N
To be Calculated:
Ratio of torque required to raise and lower the load and Efficiency of the machine
(1) Torque to raise the load (T1),
T1  F  r  W tan      r
 20 103 tan  3.64  5.71 20
 65860 N.mm
 65.86 N.m
Torque to lower the load (T2),
T2  F  r  W tan      r
 20 103 tan  5.71  3.64  20
 14457 N.mm
 14.46 N.m
T1 65.86
Ratio    4.56
T2 14.46
(2) The efficiency of the machine,
tan 
Efficiency  
tan     
tan 3.64

tan  3.64  5.71
 0.3863
  38.63
Ex. 6.9 In a screw jack, the diameter of the threaded screw is 40 mm and the pitch is 8 mm. The
load is 20 KN and it does not rotate with the screw but is carried on a swivel head having a
bearing diameter of 70 mm. The coefficient of friction between the swivel head and the
spindle is 0.08 and between the screw and nut is 0.1. Determine the total torque required
to raise the load and efficiency.
d = 40mm, p = 8mm, W = 20KN, D = 70mm,μ = 0.1 = tanφ, μ1= 0.08

To be Calculated:
The total torque required to raise the load and the efficiency

p 8
tan     0.0637   3.64 &   tan      tan 1  0.1  5.71
d  40
 20 103 tan  3.64  5.71
 3293.049 N
 Torque to raise the load  Torque due to collar friction
d
 F   1WR
2
40
 3293.049   0.08  20 103  35
2
 121860.98 N.mm
T  121.86 N.m
tan  W.D. in lifting load / rev

Efficiency   or 
tan      W.D. by applied force / rev
tan 3.64 WP W 20 103 tan 3.64
   tan  
tan  3.64  5.71 F  d F 3293.049
 0.3863  0.3863
  38.63   38.63
Ex. 6.10 A screw jack raises a load of 16 KN through a distance of 150 mm. The mean diameter and
the pitch of the screw are 56 mm and 10 mm respectively. Determine the work done and
the efficiency of the screw jack when the
i. Load rotates with the screw
ii. Loose head on which the load rests does not rotate with the screw and the outside
and the inside diameters of the bearing surface of the loose head are 50 mm and
10 mm respectively.
Take µ =0.11.
d = 56 mm, p = 10 mm, W = 16 KN, h = 150 mm, μ = 0.11= tan φ, μ1= 0.08
To be Calculated:
Work done and the efficiency of the screw jack
p 10
tan     0.0568   3.25 &   tan      tan 1  0.11  6.28
d  56
Torque to raise the load T1  F  r
 W tan      r
0.056
 16  103 tan  3.25  6.28 
2
T1  75.21 N.m

In one complete revolution distance moved by screw = pitch = 10 mm
150 (dist .)
 Number of revolutions by screw   15
10 (pitch)
(1) When the load rotates with screw

Work done in raising the load/rev = T.2
 Total work done in raising the load  T.2.N

 75.21 215
 7088 N.m
tan 
Efficiency  
tan     
tan 3.25

tan  3.25  6.28 
 0.3382
  33.82
(2) When the load does not rotate with the screw
1  50  10 
Mean diameter of bearing surface R     15 mm
2 2 
Torque due to collar friction T2  WR

 0.1116 103  0.015
T2  26.4 N.m
Total friction torque required to raise the load,
T  T1  T2
 75.21  26.4
T  101.61N.m
 Total work done in raising the load  T.2.N
 101.61 215
 9577 N.m
W.D. in lifting load / rev

Efficiency  
W.D. by applied force / rev
WP W 16 103 tan 3.25
  tan  
F  d F 3629
 0.25
  25
Ex. 6.11 In a thrust bearing, the external and the internal diameters of the contacting surface are
320 mm and 200 mm respectively. The total axial load is 80 KN and the intensity of
pressure is 350 KN/m2. The shaft rotates at 400 RPM. Taking the µ=0.06. Calculate the

power lost in overcoming the friction. Also, find the number of collars required for the
bearing.
d1 = 320mm,d2 = 200mm,W = 80KN, P = 350KN/m2N = 400rpm, μ = 0.06
To be Calculated:
Power lost in overcoming the friction and the number of collars required for the bearing
Using uniform pressure theory torque,
2  R 3  R 32 
T  W  12 2 
3  R1  R 2 
3  0.16    0.10 
2  3 3

  0.06  80 10  
  0.16    0.10  
2 2
3
3200  3.096 103


0.0156
T  635.07 N.m
Power lost in friction (Pf),
Pf  T.
2N
 T
60
2 400
 635.07 
60
 26602.03 W
Pf  26.60 kW
Number of collars required (n),

W
P

n R12  R 22 
W
 n

P R12  R 22 
80 103

350 103   0.16    0.10  
2 2
 
 4.66
n 5
Ex. 6.12 A conical pivot with the angle of the cone as 100° supports a load of 18 KN. The external
radius is 2.5 times the internal radius. The shaft rotates at 150 RPM. If the intensity of
pressure is to be 300 KN/m2 and coefficient of friction as 0.05, what is the power lost in
working against the friction?
2α=100°, W = 18KN,R1 = 2.5R2,N = 150rpm, P = 300KN/m2, μ = 0.05
To be Calculated:
Power lost in overcoming the friction
W
Let P 
  R12  R 22 
18 103
300 103 

  2.5R 22  R 22 
  
 R1  0.0603 m
 R 2  0.1508 m
2  R13  R 32 
Let T  W cosec  2 2 
3  R1  R 2 
2   0.15083   0.06033 
  0.05 18 10  cosec50 
3

  0.1508    0.0603 
2 2
3
783.244  3.2100 103


0.01910
T  131.63 N.m
Power lost in friction (Pf),
Pf  T.
2N
 T
60
2150
 131.63 
60
 2067 W
Pf  2.067 kW
Ex. 6.13 A thrust bearing of a propeller shaft consists of a number of collars. The shaft is of 400
mm diameter and rotates at a speed of 90 rpm. The thrust on the shaft is 300 KN. If the
intensity of pressure is to be 200 KN/m2 and the coefficient of friction is 0.06. Determine
the external diameter of the collar and the number of collars. The power lost in friction is
not to exceed 48 KW.
R2 = 200 mm, N = 90 rpm, W = 300 KN, P = 200 KN/m2 = 0.2 N/mm2, μ = 0.06, Pf = 48 kW
To be Calculated:
External diameter of the collar and the number of collars
2NT
Let Pf 
60
2 90  T
48 103    T  5093 N.m
60

2  R 3  R 32 
Let T  W  12 2 
3  R1  R 2 
2
 W 

  R1  R 2  R12  R 22  R1R 2  

3 

 R1  R 2  R1  R 2  

2
5093 103   0.06  300 103 
2

 R1  200  200R1
2
 
3 

 R1  200  

R1  352 mm (Taking positive sign only)
W
P

n R12  R 22 
W
 n

P R12  R 22 
300 103

0.2 3522  2002 
 5.69
n6
Ex. 6.14 The inner and the outer radii of a plate clutch are 40 mm and 80 mm respectively.
Determine the maximum, minimum and the average pressure when the axial force is 3 KN.
Solution: Maximum pressure will be at inner radius,
F  2Pi R i  R o  R i  F  2Pr  R o  R i  
3000  2Pi 0.04  0.08  0.04 
Pi(max)  298.4 103 N / m 2

Pi(max)  298.4 kN / m 2
Minimum pressure will be at outer radius,
F  2Po R o  R o  R i 
3000  2Po 0.08  0.08  0.04 
Po(min)  149.2 103 N / m 2
Po(min)  149.2 kN / m 2
Total Normal Force 3000

Average pressure    189.9 103 N / m 2
C / S Area 
 0.08  0.04
2 2

Ex. 6.15 A single plate clutch is required to transmit 8 KW at 1000 RPM. The axial pressure is limited
to 70 KN/m2. The mean radius of the plate is 4.5 times the radial width of the friction
surface. If both sides of the plate are effective and the coefficient of friction is 0.25. find
the inner and the outer radii of the plate and the mean radius and width of the friction lining.

P = 8KW, N = 1000 rpm, Pi = 70 KN/m2, μ = 0.25 = tan φ
To be Calculated:
Inner and the outer radii of the plate and the mean radius, Width of the friction lining
Ro  Ri
Let R m   4.5  R o  R i   4.5b
2
Ro  Ri  9 Ro  Ri 
8R o  10R i
R o  1.25R i
In the clutch, it is safer to apply uniform wear theory and maximum pressure is at the inner
radius, i.e., Pi = 70 KN/m2
P  T
21000
8 103  T 
60
 T  76.39 N.m
1 n  Number of surfaces  2
 
Torque, T  F  R o  R i  n  
2 F  2Pi R i  R o  R i 
 


  2Pi R i  R o  R i    R o  R i  2
2
76.39    2 70 103  R i 1.25R i  R i   1.25R i  R i 
76.39  0.25  2 70 103  0.5625R 3i
 R i  0.1073 m
 R o  0.1341 m
R m  4.5  R o  R i 
 4.5  0.1341  0.1073
 R m  0.1207 m
R m 0.1207
Width w  
4.5 4.5
 0.0268 m
w  26.8 mm
Ex. 6.16 A single plate clutch transmits 25 KW at 900 RPM. The maximum pressure intensity
between the plates is 85 KN/m2. The outer diameter of the plate is 360 mm. Both sides of
the plate are effective and the coefficient of friction is 0.25. Determine
i. The inner diameter of the plate
ii. Axial force to engage the clutch.

P = 25 KW, N = 900 rpm, Pi = 85 KN/m2, μ = 0.25 = tan φ, Ro = 0.180 m

To be Calculated:
Inner diameter of the plate and Axial force to engage the clutch
Let P  T
2 900
25 103  T 
60
 T  265.25 N.m
1 n  Number of surfaces  2
 
Torque, T  F  R o  R i  n  
2 F  2Pi R i  R o  R i 
 


  2Pi R i  R o  R i    R o  R i  n
2
265.25  0.25   85 103  R i  0.18  R i  0.18  R i  2
R i  0.1315 m
 R i  131.5 m m
Axial force, F  2Pi R i  R o  R i  n
 2 85  103  0.1315  0.18  0.1315 2

 6812 N
F  6.812 kN
Ex. 6.17 A friction clutch is used to rotate a machine from a shaft rotating at a uniform speed of
250 rpm. The disc type clutch has both of its sides effective, the coefficient of friction is
0.3. The outer and the inner diameters of the friction plates are 200 mm and 120 mm
respectively. Assuming uniform wear of the clutch, the intensity of pressure is not to be
more than 100 KN/m2. If the moment of inertia of the rotating parts of the machine is 6.5
kg.m2. Determine the time to attain the full speed by the machine and the energy loss in
the slipping of the clutch. What will be the intensity of pressure if the condition of uniform
pressure of the clutch is considered? Also, determine the ratio of power transmitted with
uniform wear to that with uniform pressure.
N = 250 rpm, μ = 0.3, Ro = 0.100 m, Ri = 0.060 m, Pi = 100 KN/m2, Ro = 0.180 m, I =65 Kg.m2
(i) Time to attain full speed in uniform wear condition
F  2Pi R i  R o  R i 
 2100 103  0.06  0.1  0.06 
 1508 N
F
Torque T  Ro  Ri  n
2
0.3 1508
  0.1  0.06  2
2
 72.38 N.m

2N 2 250
Power  T.  T   72.38   1895 W
60 60
Also Torque T  I.   Angulr acceleration
72.38  6.5  
   11.135 rad / s 2
 2N
Let   
t 60t
22  50
11.135 
60  t
 t  2.35 s
(ii) The energy lost during the slipping period

Angle turn by driving shaft (θ1),
2N 2 250
1  t  t  2.35  61.5 rad
60 60
Angle turn by driving shaft (θ2),
1 1
2  o t  t 2  0  11.135  2.352  30.75 rad
2 2
The energy lost during the slipping period  T  1  2 
 72.38  61.5  30.75 

 2226 N.m
 2.226 kN.m
(ii) Pressure in uniform pressure condition and ratio
F 1508
P   75000 N / m2  75 kN / m 2
  R o2  R i2  
 0.1  0.06
2 2

2  R 3o  R i3 
Also T  F  2 n
3  R o  R i2 
2  0.13  0.063 
  0.3 1508  2 2 
2 n  Number of surface  2
3  0.1  0.06 
 73.89 N.m
2N 2 250

Power  T.  T   73.89   1934 W
60 60
Power with uniform wear 1895
Now   0.98
Power with uniform pressure 1934
Ex. 6.18 A multi-plate disc clutch transmits 55 KW of power at 1800 RPM. The coefficient of friction
for the friction surface is 0.1. The axial intensity of the pressure is not to exceed 160

KN/m2, the internal radius is 80 mm and is 0.7 times the external radius. Find the number
of the plates needed to transmit the required torque.
P = 55 KW, N = 1800 rpm, μ = 0.1, Pi = 160 KN/m2, Ri = 0.080 m, Ri = 0.7 Ro, Ro = 0.1143 m
To be Calculated:
Number of the plates
Assuming uniform wear condition,
F  2Pi R i  R o  R i 
 2160 103  0.08  0.1143  0.08 
 2759 N
1
T  F  R o  R i 
2
1
  0.1 2759  0.1143  0.08 
2
 26.78 N.m / surface
Total torque transmitted,
P 55 103
T   291.8 N.m
 21800
60
291.8
Number of friction surface required n   10.9  11
26.78
Note: There will be 12 plates. 6 plates (rings) revolve with the driving or engine shaft and the
other 6 with the driven shaft.
Ex. 6.19 A multi-plate disc clutch transmits 30 KW of power at 1800 RPM. It has four discs on the
driving shaft and three discs on the driving shaft and three discs on the driven shaft
providing six pairs of contact surfaces. The external and internal diameters of the contact
surface are 200 mm and 100 mm respectively.
Assuming the clutch to be new, find the total spring load pressing the plates together. The
coefficient of friction is 0.3.
Also, determine the maximum power transmitted when the contact surface has worn away
by 0.4 mm. There are 8 springs and the stiffness of each spring is 15 KN/m.
P = 30KW, N = 1800rpmμ = 0.3, contact surface = 6 pair = 12, Ro = 100mm, Ri = 50mm,
8 springs with stiffness k = 15KN/m = 15N/mm
To be Calculated:
The total spring load and the maximum power transmitted
New clutch has uniform pressure distribution

Let P  T
21800
30 103  T    T  159.15 N.m
60
Torque transmitted by a new clutch,
2  R 3  R 3i 
T  F  2o n
3  R o  R i2 
2  1003  503 
159.15   0.3  F  2 
 100  50 
2
3
 F  1137 N
When the surfaces are worn out,

Total wear = Number of surfaces x wear on each surface
= 12 x 0.4 = 4.8 mm
Total spring stiffness = 8 x 15 = 120 N/mm
So reduction in spring force = 120 x 4.8 = 576 N
New axial load = 1137−576 = 561 N
Let torque (wear on clutch and uniform wear theory)
1 1
T  F  R o  R i  n   0.3  561 0.1  0.05  6
2 2
 75.735 N.m
Maximum power transmitted,
Pmax  T.
21800
 75.735 
60
Pmax  14.275 kW
Ex. 6.20 A torque of 350 N.m is transmitted through a cone clutch having a mean diameter of 300
mm and a semi cone angle of 15°. The maximum normal pressure at the mean radius is
150 KN/m2. The coefficient of friction 0.3. Calculate the width of the contact surface. Also,
find the axial force to engage the clutch.
T = 350 Nm, Dm = 300mm Rm =150 mm, α = 15°, Pmax = 150 KN/m2, μ = 0.3
To be Calculated:
The width of the contact surface and the axial force to engage the clutch
For cone clutch,
T  Fn R m
350  0.3  Fn  0.150
 Fn  7778 N

and Fn  2Pmax R m b
7778  2150 103  0.150  b
 b  0.055 m
 b  55 mm
Axial force,
F  Fn sin 
 7778  sin15
F  2012.4 N
Ex. 6.21 The semi cone angle of a cone clutch is 12.5° and the contact surfaces have a mean
diameter of 80 mm. coefficient of friction 0.32. What is the minimum torque required to
produce slipping of the clutch for an axial force of 200 N? If the clutch is used to connect
an electric motor with a stationary flywheel, determine the time needed to attain the full
speed and the energy lost during slipping. Motor speed is 900 rpm and the moment of
inertia of the flywheel is 0.4 KG.m2.
α = 12.5°, Rm =0.04 m, μ = 0.32, F = 200 N, N = 900 rpm, I = 0.4 KG.m2
To be Calculated:
Minimum torque required and time needed to attain the full speed
Let Torque
T  I. a  a  Angular acceleration
Fn R m  I. a
F
 R m  I. a
sin 
200
0.32   0.04  0.4   a
sin12.5
  a  29.57 rad / s 2
Also Torque T  I. a

 0.4  29.57
T  11.828 N.m

a 
t
2 900
29.57  60   t  3.187 s
t
During slipping period

2 900
Angle turned by the driving shaft, 1  .t   3.187  300.4 rad
60

1 1
 a t 2  0   29.57   3.187   150.2 rad
2
Angle turned by the driven shaft, 2  0 t 
2 2
The energy lost in friction  T  1  2   11.828  300.4  150.2   1776.5 N.m

Ex. 6.22 A cone clutch with a semi cone angle of 15° transmits 10 KW at 600 RPM. The normal
pressure intensity between the surface in contact is not to exceed 100 KN/m2. The width
of the friction surface is half of the mean diameter. Assume µ=0.25. Determine the
i. Outer and inner diameters of the plate
ii. Width of the cone face
iii. Axial force to engage the clutch

α = 15°, P=10 KW, N = 600 rpm, Pi = 100 KN/m2, b = Dm/2 = Rm, μ = 0.25
To be Calculated:
Ro, Ri, b and F
(i) Let b = Rm
Ro  Ri Ro  Ri

sin  2
 R  Ri 
 R o  R i  sin15  o
 2 
 R o  R i  0.129R o  0.129R i
 R o  0.129R o  0.129R i
Now Power, P  T.

2 600
10 103  T    T  159 N.m
60
Applying uniform wear theory (Intensity of pressure is maximum at inner radius)
T  Fn
Ro  Ri 
2
F Ro  Ri 

sin  2

  2.Pi .R i  R o  R i    R o  R i 
2sin  
Pi

sin 

R i R o2  R i2 
0.25  100 103 
R i 1.296R i   R i2 
2
159 
sin15  
 R i  0.0917 m  91.7 mm
 R o  91.7 1.296  118.8 mm
(ii) Width of cone face (b),

R o  R i 118.8  91.7
b   105 mm
sin  sin15
(iii) Axial force (F),
F  2Pi R i  R o  R i 
 2100 103  0.0917  0.1188  0.0917 
 F  1561 N
Ex. 6.23 A centrifugal clutch transmits 20 KW of the power at 750 RPM. The engagement of the
clutch commences at 70% of the running speed. The inside diameter of the drum is 200
mm and the distance of the center of mass of each shoe is 40 mm from the contact surface.
Assume µ=0.25 and spring stiffness 150 KN/m. Determine:
i. Mass of each shoe
ii. Net force exerted by each shoe on the drum surface
iii. Power transmitted when the shoe is worn 2 mm and is not readjusted.

n = 4, P=10 KW, N = 750 rpm, Pi = 100 KN/m2, μ = 0.25, R = 200 mm, r = 0.2−0.04 = 0.16 m
To be Calculated:
m, F and P
(i) Mass of shoe (m)
2 750
  78.53 rad / s   '  0.7  78.5  55 rad / s
60
P  T.
20 103  T  78.53  T  254.8 N.m

The total frictional torque acting  mr 2   '2 .R.n 

254.8  0.25  m  0.16 78.52  552 0.2  4 
 m  2.538 kg
(ii) Net force exerted by each shoe on the drum surface

 mr 2   '2 
 2.538  0.16  78.5 2
 552 
 1274 N
(iii) Spring force exerted by each spring = 2.538 x 0.16 x 552
= 1228.4 N
When the shoe wears 2 mm, each shoe has to move forward by 2 mm. This increases the
distance of the center of mass of the shoe from 160 mm to 162 mm. Also, the spring force
is increased due to its additional displacement of 2 mm.
Additional spring force = Stiffness x Displacement
= 150 x 103 x 0.002
= 300 N

Total spring force = 1228.4 + 300 = 1528.4 N
Net force exerted by each shoe on the drum surface
 mr2  1528.4
 2.538  0.162  78.52  1528.4
 1005.2 N
Total frictional torque acting  F.R.n
T  0.25 1005.2  0.2  4  201.04 N.m

P  T
 201.04  78.5
 15782 W
P  15.782 kW
Ex. 6.24 A brake as shown in the below figure is fitted with a C.I. brake shoe.
The braking torsional moment = 360 N.m
The drum diameter = 300 mm
The coefficient of friction = 0.3
Find:
(i) force P for counter-clockwise rotation
(ii) force P for clockwise rotation
(iii) where must pivot be placed to make brake self-locking with clockwise rotation
Solution:
Given data:
Tb = 360 N.m, d = 300 mm, μ = 0.3
(a) (b)
For the clockwise rotation of the brake drum, the frictional force or the tangential force (F t)
acting at the contact surfaces is shown in Fig. (a)
Braking torque, Tb = Ft x r
= μ RN x r
360 = 0.3 x RN x 0.15
Normal force, RN = 8000 N
Now taking moments about the fulcrum O,
P (600 + 200) + Ft x 50 = RN x 200
P x 800 + (0.3 x 8000) 50 = 8000 x 200
P x 800 = 1480 x 103
P = 1850 N
For the counterclockwise rotation of the brake drum, the frictional force or the tangential
force (Ft) acting at the contact surfaces is shown in Fig. (b)
Now taking moments about the fulcrum O,
P (600 + 200) = Ft x 50 + RN x 200
P x 800 = (0.3 x 8000) 50 + 8000 x 200
P x 800 = 1720 x 103
P = 2150 N
Location of the pivot or fulcrum to make the brake self-locking
The clockwise rotation of the brake drum is shown in Fig. (a). Let x be the distance of the
pivot or fulcrum O from the line of action of the tangential force (F t). Taking moments about
the fulcrum O,
P (600 + 200) + Ft (x) – RN x 200 = 0
In order to make the brake self-locking, Ft (x) must be equal to RN x 200, so that the force P
is zero.
Ft (x) = RN x 200
2400 (x) = 8000 x 200
x = 667 mm
Ex. 6.25 A simple band brake is shown in Figure below is applied to a shaft carrying a flywheel of
mass 400 kg. The radius of gyration of the flywheel is 450 mm and runs at 300 RPM. The
coefficient of friction is 0.2 and the brake drum diameter is 240 mm. Take b = 120 mm, l =
420 mm,  = 210, then find out the followings:
(i) The torque applied due to hand load of 100 N
(ii) The number of turns of the flywheel before it is brought to rest
The time required to bring it to rest from the moment of the application of the brake.
Solution:

Given data:
m = 400 kg, k = 450 mm, N = 300 rpm, μ = 0.2, d = 240 mm,  = 210 = 3.665 rad
Taking moments about the fulcrum O,
T1 x b = P x l
T1 x 0.12 = P x 0.42
T1 x 0.12 = 100 x 0.42
T1 = 350 N
Now,
T1
 e  e0.23.665
T2
T1
 2.081
T2
T1 350
T2  
2.081 2.081
T2 = 168.188 N
Braking torque,
Tb = F t x r
= (T1– T2) x r
= (350 – 168.188) x 0.12
= 21.817 N.m
Work done against friction due to absorption of K.E.
1
Ft  S  mv 2
2
1
Ft  S  m (r) 2
2
m  dN 
2
S  
Ft  2  60 
400   0.24  300 

2
S  
181.81 2  60 
= 15.63 m
S=Dxn
S
No. of turns, n 
D
15.63

 0.24

= 20.73
Tb = I α
= (mk2) α
21.817 = (400 x 0.4502) α
α = 0.269
 = o + αt
 2N 
0   t
 60 
 2 300 
0   0.269  t
 60 
t = 116.78 sec
Ex. 6.26 A band brake shown in the Figure below is used to balance a torque of 980 N-m at the drum
shaft. The drum diameter is 400 mm (rotating in the clockwise direction) and the allowable
pressure between lining and drum is 0.5 MPa. The coefficient of friction is 0.25. Design
the steel band, shaft, brake lever, and fulcrum pin, if all these elements are made from
steel having permissible tensile stress 70 MPa and shear stress 50 MPa.
Solution:
Given data:
Tb = 980 N.m, d = 400 mm, p = 0.5 MPa, μ = 0.25, σt = 70 MPa, τ = 50 MPa,
 = 120 = 2.094 rad
Braking torque,
Tb = F t x r
= (T1– T2) x r
980 x 103 = (T1– T2) x 200
T1– T2 = 4.9 x 103
Now,
T1
 e  e0.252.094
T2
T1
 1.688
T2

1.688 T2– T2 = 4.9 x 103
T2 = 7122.09 N
T1 = 12022.09 N
Taking moments about the fulcrum O,
T2 x 80 = P x 600
7122.09 x 80 = P x 600
P = 949.612 N
Design of Shaft
Since the shaft has to transmit torque equal to the braking torque
 3
Tb  dS 
16
 3
980 103  dS  50
16
dS = 46.388 mm
Shaft diameter, dS ≈ 50 mm
Design of Lever
t1 = thickness of the lever
B = width of the lever
Maximum bending moment at fulcrum O due to force P,
M = P x l = 949.612 x 600
= 569767.2 N.mm
Section modulus,
1 1
Z  t1  B2  t1  (2t1 ) 2
6 6 (Assuming B = 2t1)
= 0.67 t13 mm3
M
Bending stress 
Z
569767.2
70 
0.67 t13
t1 = 22.988 mm ≈ 23 mm
B = 2t1
= 46 mm
Design of Pins
d1 = diameter of pins
l1 = length of pins = 1.25 d1

The pins are designed for maximum tension in the band (i.e. T 1 = 12022.09 N)
Considering bearing of the pins, maximum tension (T 1),
12022.09 = d1.l1.p = d1 x 1.25 d1 x 0.5
d1 = 138.69 mm
d1 ≈ 140 mm
l1 = 1.25 d1 = 1.25 x 140
= 175 mm
Check the pin for induced shearing stress. Since the pin is in double shear, therefore
maximum tension (T1),
 
12022.09  2  (d12 )  2  (140) 2 
4 4
 30787.6
12022.09

30787.6
= 0.39 MPa
This induced stress is quite within permissible limits.
The pin may be checked for induced bending stress.
5 5
Maximum bending moment, M   W.l1  12022.09 175
24 24 (W= T1)
= 438305.36 N-mm
 3 
sec tion modulus, Z  (d1 )  (140)3
32 32
 269391.57 mm3
M 438305.36
Bending stress  
Z 269391.57
=1.627 MPa
The induced bending stress is within safe limits of 70 MPa.
The lever has an eye hole for the pin and connectors at band have a forked end.
l1 175
Thickness of each eye, t 2    87.5 mm
2 2
Outer diameter of the eye, D= 2d1 = 2 x 140 = 280 mm
A clearance of 1.5 mm is provided on either side of the lever in the fork.
A brass bush of 3 mm thickness may be provided in the eye of the lever.
Diameter of hole in the lever = d1 + 2 x 3 = 140 + 2 x 3 = 146 mm

The boss is made at pin joints whose outer diameter is taken equal to twice the diameter of
the pin and length equal to the length of the pin.
The inner diameter of the boss is equal to the diameter of the hole in the lever.
Outer diameter of the boss = 2d1 = 2(140) = 280 mm
Length of the boss = l1 = 175 mm
Check the bending stress induced in the lever at the
fulcrum.
Maximum bending moment at the fulcrum,
M = P x l = 949.612 x 600
= 569767.2 N-mm
1
175  2803  1463 
Sec tion modulus, Z  12
280 / 2
= 1962485.83 mm3
M 569767.2
Bending stress    0.29 MPa
Z 1962485.83
The induced bending stress is within safe limits of 70 MPa.
Ex. 6.27 A differential band brake has a drum with a diameter of 800 mm. The two ends of the band
are fixed to the pins on the opposite sides of the fulcrum of the lever at distances of 40
mm and 200 mm from the fulcrum. The angle of contact is 270° and the coefficient of
friction is 0.2. Determine the brake torque when a force of 600 N is applied to the lever at
a distance of 800 mm from the fulcrum.
Differential Band Brake

d  800 mm  r  400 mm
  270
  0.2
Assuming a = 200 mm, b = 40 mm, i.e., a > b, F must act downward direction to apply the
brake.
(a) Anticlockwise Rotation
Taking moment about fulcrum O,

F  l  T1 a  T2 b  0
600  800  (2.57 T2 ) 200  T2  40   0
T2  1012.7 N and
T1  2602.5N
 T1 
  270 


  e  e 180

 T2 
 
 T1  2.57 
 T2 
Braking Torque,  
TB  T1  T2 r  2602.5  1012.7  0.4  635.92 N  m
(b) Clockwise Rotation

F  l  T1 b  T2 a  0
600  800  2.57 T2  40   T2 200   0
T2  4938 N and
T1  2.57 T2  12691N
TB  T1  T2 r  12691  4938  0.4  3101 N  m
Assuming a = 40 mm, b = 200 mm, i.e., a < b, F must act upward to apply the brake.
(a) Anticlockwise Rotation

F  l  T1 a  T2 b  0
600  800  2.57 T2 (40)  T2 200   0
T2  4938 N and
T1  12691 N
TB  T1  T2 r  12691  4938  0.4  3101 N  m
(b) Clockwise Rotation

F  l  T2 a  T1 b  0
600  800  T2  40   2.57 T2 200   0
T2  1012.7 N and
T1  2602.5N
TB  T1  T2 r  1012.7  2602.5 0.4  636 N  m
Note: The above results show that the effectiveness of the brake in one direction of rotation
is equal to the effectiveness in the other direction if the distance of the pins on the opposite
sides of the fulcrum is changed and the force is applied in the proper direction so that the
band is tightened.
Ex. 6.28 A simple band brake is applied to a shaft carrying a flywheel of 250 kg mass and of the
radius of gyration of 300 mm. the shaft speed is 200 rpm. The drum diameter is 200 mm
and the coefficient of friction is 0.25. Determine the
1. brake torque when a force of 120 N is applied at the lever end
2. number of turns of the flywheel before it comes to rest
3. time is taken by the flywheel to come to rest.
Solution:

Given data:
m  250 kg
k  300 mm
N  200 rpm
d  200 mm
  0.25

  360  135  225   3.93rad
180
1. Taking moment about O,
F  l  T1  a
120  280  T1  100  T1  0.25  3.93 
 e e 
T1  336 N  T2 
 
T  T1  2.67 
T2  1  125.8 N  T2 
2.67
TB  T1  T2 r   336  125.8  0.1  21 N  m
2. K.E of the flywheel

2
1 1  2N 
 I 2  m k2   
2 2  60 
2
1  2  200 
  250  0.32  
2  60 
 4935 N  m
This K.E is used to overcome the work done by the braking torque in n revolutions.
K. E of flywheel  TB  Angular displacement

4935  21  2  n
n  37.4 Revolution
3. For uniform retardation,

200
Average speed   100 rpm
2
n 37.4 37.4
 Time taken   min.   22.44 sec
N 100 100 / 60
Ex. 6.29 A simple band brake is applied to a drum of 560 mm diameter which rotates at 240 RPM.
The angle of contact of the band is 270°. One end of the band is fastened to a fixed pin and
the other end to the brake lever, 140 mm from the fixed pin. The brake lever is 800 mm
long and is placed perpendicular to the diameter that bisects the angle of contact.
Assuming the coefficient of friction as 0.3, determine the necessary pull at the end of the
lever to stop the drum if 40 kW of power is being absorbed. Also, find the width of the band
if its thickness is 3 mm and the maximum tensile stress is limited to 40 N/mm 2.

Solution:
Given data:
d  560 mm N  240 rpm
  270 a  140 mm ,
l  800 mm   0.3
P  40 kW
thickness t  3mm
  40 N / mm2
Note: It can be observed from the figure that to tighten the band, the force is to be applied
upwards. If the drum rotates counterclockwise, the tight and slack sides will be as shown.
P  TB  
2N
  T1  T2  r 
60
2  240
40  103   T1  T2  0.28 
60
 T1  T2  5684 ________(1)
and

T1 
0.3  270 
e e 180
 4.11 _______(2)
T2
T2  1828 N
T1  7514 N
Taking the moment about O,
F  l  T2  140 cos 45
F  800  1828  140 cos 45
F  226.2 N

Let maximum tension,
T1    b  t
7514  40  b  3
b  62.6 mm
Note: If the drum rotates clockwise, the brake is less effective as in that case tight and slack
sides are interchanged and the force required to apply the same braking torque is more.
F  l  T1  140 cos 40
F  800  7514  140 cos 40
F  930 N
Ex. 6.30 A crane is required to support a load of 1.2 tonnes on the rope around its barrel of 400 mm
diameter. The brake drum which is keyed to the same shaft as the barrel has a diameter of
600 mm. The angle of contact of the band brake is 275° and the coefficient of friction is
0.22. Determine the force required at the end of the lever to support the load. Take a = 150
mm and l = 750 mm.
Solution:
Given data:
W  1.2  1000  9.81N
R  300 mm r  200 mm
  0.22   275
For equilibrium position,
T 1 
 T2 R  W  r
2.87 T 2 
 T2 300  1.2  1000  9.81  200
 T2  4197 N  m  T1 
0.22  275 


  e  e 180
 2.87
and T1  12045N  m  T2 
Taking moment about O,
F  l  T1  a
F  750  12045  150
F  2409 N

Ex. 6.31 A band and block brake has 14 blocks. Each block subtends an angle of 14° at the center
of the rotating drum. The diameter of the drum is 750 mm and the thickness of the blocks
is 65 mm. The two ends of the band are fixed to the pins on the lever at distances of 50
mm and 210 mm from the fulcrum on the opposite sides. Determine the least force
required to be applied at the lever at a distance of 600 mm from the fulcrum if the power
absorbed by the blocks is 180 kW at 175 RPM. The coefficient of friction between the
blocks and the drum is 0.35.
n  14 blocks 2  14
d  750 mm t  65mm
a  210 mm , b  50 mm
l  600 mm P  180 kW
N  175rpm   0.35
F?
P   T14  T0  v
DN
  T14  T0 
60
180  103   T14  T0 

 0.75  2  0.065  175
60
 T14  T0   22323N _____(1)
n
T14  1   tan  
  
T0  1   tan  
14
T14  1  0.35 tan7 
    3.334 _______(2)
T0  1  0.35 tan7 
From equation (1) and (2)
T0  9564 N
T14  31887N
Assume a > b, F must be a downward and clockwise rotation for maximum braking torque.
The moment about O,
F  l  T0 a  T14 b  0
F  600  9564  210  31887  50  0
F  690 N
Ex. 6.32 A band and block brake having 12 blocks, each of which subtends an angle of 16° at the
center, is applied to a rotating drum with a diameter of 600 mm. The blocks are 75 mm
thick. The drum and the flywheel mounted on the same shaft have a mass of 1800 kg and
have a combined radius of gyration of 600 mm. The two ends of the band are attached to
pins on the opposite sides of the brake fulcrum at distances of 40 mm and 150 mm from
it. If a force of 250 N is applied on the lever at a distance of 900 mm from the fulcrum, find
the
1. Maximum braking torque
2. Angular retardation of the drum
3. Time is taken by the system to be stationary from the rated speed of 300 rpm.
  16 n  12 blocks
d  600 mm t  75mm
m  1800 kg k  600 mm
a  150 mm , b  40 mm
F  250 N l  900 mm
N  300 rpm   0.3
n
T12  1   tan  
  
T0  1   tan  
12
T14  1  0.3 tan8 
    2.752
T0  1  0.3 tan8 
Assume a = 150 mm, b = 40 mm as a > b, F must be downwardsand rotation is clockwise.

F  l  T0 a  T12 b  0
250  900  T0 (150)  T12  40   0
T0 150  2.752  40   250  900
 T0  5636 N
T12  15511 N

Maximum Braking torque,

TB  T12  T0 r
0.6  0.075  2
 15511  5636  
2  d d  2 t 
 r  
 3703N  m  2 2 
2. Let braking torque
TB  I    m k2  
3703  1800  0.6   
2
  5.71 rad / sec2
3. Initial Angular Speed
  0   t
   Final Angular speed  0 
0  31.4  5.71 t  
   2  N  2   300  31.4 rad / sec 
t  5.5 sec 

0
60 60 

Ex. 6.33 A car moving on a level road at a speed 50 km/h has a wheelbase 2.8 meters, the distance
of C.G. from ground level 600 mm, and the distance of C.G. from rear wheels 1.2metres.
Find the distance traveled by car before coming to rest when brakes are applied,
1. to the rear wheels,
2. to the front wheels, and
3. to all the four wheels.
The coefficient of friction between the tyres and the road may be taken as 0.6.
u  50 km / hr  13.89 m / sec
L  2.8 m h  600 mm
x  1.2 m   0.6
1. Rear Wheels
Here vehicle moves on a level road, so retardation of the car is
 g (L  x) 0.6  9.81  2.8  1.2 

a   2.98 m / sec2
L h 2.8  0.6  0.6
If retardation is uniform,
v2  u2   2 s a
0  u2   2 s a
u2 13.892
s    32.4 m
2 a 2  2.98
2. Front Wheels
gx 0.6  9.81  1.2

a    2.9 m / sec2
L   h 2.8  0.6  0.6
For uniform retardation,
u2
s
2a
13.892
s  33.26 m
2  2.9
3. All the four wheels

a  g   9.81  0.6  5.886 m / sec2

u2 13.892
s   16.4 m
2 a 2  5.886
Ex. 6.34 A vehicle moving on a rough plane inclined at 10° with the horizontal at a speed of 36 km/h
has a wheelbase 1.8 meters. The center of gravity of the vehicle is 0.8 meters from the
rear wheels and 0.9 meters above the inclined plane. Find the distance traveled by the
vehicle before coming to rest and the time is taken to do so when
1. The vehicle moves up the plane, and
2. The vehicle moves down the plane.
The brakes are applied to all the four wheels and the coefficient of friction is 0.5.
  10
u  36 km / h  10 m / sec
L  1.8 m
x  0.8 m
h  0.9 m
  0.5
1. The vehicle moves up (All Four wheels)
a  g   cos   sin  
 9.81  0.5 cos 10  sin10 
 6.53 m / sec2
u2 102
s   7.657 m
2 a 2  6.53
The final velocity of a vehicle
v uat ve sign due to retardation

0  10  6.53 t
 t  1.53 sec

2. The vehicle moves down the plane (All Four wheels)
a  g   cos   sin  
 9.81  0.5 cos 10  sin10 
 3.13 m / sec2
For uniform retardation
u2 102
s   16 m
2 a 2  3.13
The final velocity of a vehicle
v uat
0  10  3.13 t
 t  3.2 sec
References:

Contents
7.1 Introduction ....................................................................................................................................... 7.2

7.2 Terms Used in Gears......................................................................................................................... 7.7
7.3 Length of Path of Contact And Length of Arc of Contact ............................................................ 7.13
7.4 Interference in Involute Gears ........................................................................................................ 7.15
7.5 Comparison of Cycloidal and Involute tooth forms ...................................................................... 7.21
7.6 Helical and Spiral Gears .................................................................................................................. 7.21
7.7 Introduction to Gear Trains and Its Classification ........................................................................ 7.24
7.8 Problems .......................................................................................................................................... 7.30
7.1 Introduction
If power transmitted between two shafts is small, motion between them may be obtained by using two
plain cylinders or discs 1 and 2.
If there is no slip of one surface relative to the other, a definite motion of 1 can be transmitted to 2 and
vice-versa. Such wheels are termed as “friction wheels”. However, as the power transmitted increases, slip
occurs between the discs and the motion no longer remains definite.
Assuming no slipping of the two surfaces, the following kinematic relationship exists for their linear
velocity:
 To transmit a definite motion of one disc to the other or to prevent slip between the surfaces,
projection and recesses on the two discs can be made which can mesh with each other. This leads
to the formation of teeth on the discs and the motion between the surfaces changes from rolling
to sliding. The discs with the teeth are known as gears or gear wheels.
 It is to be noted that if the disc 1 rotates in the clockwise direction, 2 rotates in the counter-
clockwise direction and vice-versa.
Fig.7.1 – Friction Wheels
7.1.1 Advantages of gear Drive

1. It transmits an exact velocity ratio.
2. It may be used to transmit large power.
3. It has high efficiency.
4. It has a reliable service.
5. It has a compact layout.
7.1.2 Disadvantages of gear Drive

1. The manufacture of gears required special tools and equipment.
2. The error in cutting teeth may cause vibrations and noise during operation.
3. They are costly.

Unit-7 Gears and Gear Trains
7.1.3 Classification of Gears
7.1.3.1 According to the position of axes of the shafts

a) Parallel shaft
 Spur gear
The two parallel and co-planar shafts connected by the gears are called spur gears. These gears have
teeth parallel to the axis of the wheel.
They have straight teeth parallel to the axes and thus are not subjected to axial thrust due to tooth
load.
At the time of engagement of the two gears, the contact extends across the entire width on a line
parallel to the axis of rotation. This results in the sudden application of the load, high impact stresses
and excessive noise at high speeds.
If the gears have external teeth on the outer surface of the cylinders, the shaft rotates in the opposite
direction.
In internal spur gear, teeth are formed on the inner surface of an annulus ring. An internal gear can
mesh with an external pinion (smaller gear) only and the two shafts rotate in the same direction.
Fig.7.2 – Spur Gear
 Spur rack and pinion
Spur rack is a special case of a spur gear where it is made of infinite diameter so that the pitch surface
is plane.
The spur rack and pinion combination converts rotary motion into translator motion, or vice-versa.
It is used in a lathe in which the rack transmits motion to the saddle.
Fig.7.3 – Rack and Pinion

 Helical Spur Gears
In helical gears, the teeth are curved, each being helical in shape. Two mating gears have the same
helix angle but have teeth of opposite hands.
At the beginning of the engagement, contact occurs only at the point of the leading edge of the curved
teeth. As the gears rotate, the contact extends along a diagonal line across the teeth. Thus, the load
application is gradual which results in low impact stresses and reduction in noise. Therefore, the
helical gear can be used at higher velocities than the spur gears and have a greater load-carrying
capacity.
Helical gears have the disadvantage of having end thrust as there is a force component along the gear
axis. The bearing and assemblies mounting the helical gears must be able to withstand thrust loads.
Double helical: A double-helical gear is equivalent to a pair of helical gears secured together, one
having a right-hand helix and another left-hand helix.
The teeth of two rows are separated by groove used for tool run out.
Axial thrust which occurs in the case of single-helical gears is eliminated in double-helical gears.
This is because the axial thrusts of the two rows of teeth cancel each other out. These can be run at
highs speeds with less noise and vibrations.
Fig.7.4 – Helical gear
 Herringbone gear
If the left and the right inclinations of a double-helical gear meet at a common apex and there is no
groove in between, the gear is known as Herringbone gear.
Fig.7.5 – Herringbone gear

b) Intersecting Shafts
The two non-parallel or intersecting, but coplanar shafts connected by gears are called bevel gears
When teeth formed on the cones are straight, the gears are known as bevel gears when inclined, they
are known as spiral or helical bevel.
 Straight Bevel Gears
The teeth are straight, radial to the point of intersection of the shaft axes and vary in cross-section
throughout their length.
Usually, they are used to connect shafts at right angles which run at low speeds
Gears of the same size and connecting two shafts at right angles to each other are known as “Mitre”
gears.
Fig.7.6 - Straight Bevel Gears
 Spiral Bevel Gears
When the teeth of a bevel gear are inclined at an angle to the face of the bevel, they are known as spiral
bevels or helical bevels.
They are smoother in action and quieter than straight tooth bevels as there are gradual load
applications and low impact stresses. Of course, there exists an axial thrust calling for stronger
bearings and supporting assemblies.
These are used for the drive to the differential of an automobile.
Fig.7.7 – Spiral Bevel Gears

 Zero Bevel Gears
Spiral bevel gears with curved teeth but with a zero degree spiral angle are known as zero bevel gears.
Their tooth action and the end thrust are the same as that of straight bevel gears and, therefore, can
be used in the same mountings.
However, they are quieter in action than the straight bevel type as the teeth are curved.
Fig.7.8 – Zero Bevel Gear

c) Non-intersecting and non-parallel shaft (Skew shaft)
The two non-intersecting and non-parallel i.e. non-coplanar shaft connected by gears are called skew
bevel gears or spiral gears and the arrangement is known as skew bevel gearing or spiral gearing.
In these gears teeth have point contact.
These gears are suitable for transmitting small power.
A worm gear is a special case of a spiral gear in which the larger wheel, usually, has a hollow shape
such that a portion of the pitch diameter of the other gear is enveloped on it.
Fig.7.9 - Non-intersecting and non-parallel shaft

7.1.3.2 According to the peripheral velocity of the gears
a) Low velocity V < 3 m/sec
(b) Medium velocity 3 < V < 15 m/sec
(c) High velocity V > 15 m/sec
7.1.3.3 According to the position of teeth on the gear surface

(a) Straight,
(b) Inclined, and
(c) Curved
7.2 Terms Used in Gears

1. Pitch circle. It is an imaginary circle which by the pure rolling action, would give the same motion as the
actual gear.
2. Pitch circle diameter. It is the diameter of the pitch circle. The size of the gear is usually specified by
the pitch circle diameter. It is also known as pitch diameter.
3. Pitch point. It is a common point of contact between two pitch circles.
4. Pitch surface. It is the surface of the rolling discs which the meshing gears have replaced at the pitch
circle.
Fig.7.10 - Terms used in gears
5. Pressure angle or angle of obliquity. It is the angle between the common normal to two gear teeth at
the point of contact and the common tangent at the pitch point.
For more power transmission lesser pressure on the bearing and pressure angle must be kept small.
It is usually denoted by ø.
1
The standard pressure angles are 20° and 25°.Gears with 14 ° pressure angle has become obsolete.
2

6. Addendum. It is the radial distance of a tooth from the pitch circle to the top of the tooth.
 Standard value = 1 module
7. Dedendum. It is the radial distance of a tooth from the pitch circle to the bottom of the tooth.
 Standard value = 1.157 module
8. Addendum circle. It is the circle drawn through the top of the teeth and is concentric with the pitch
circle.
9. Dedendum circle. It is the circle drawn through the bottom of the teeth. It is also called the root circle.
10. Clearance. It is the radial difference between the addendum and the Dedendum of a tooth.
Addendum circle diameter  d  2m
Dedendum circle diameter  d  2  1.157m
Clearance  1.157m  m  0.157m

11. Full-depth of Teeth It is the total radial depth of the tooth space.
Full depth= Addendum + Dedendum
12. Working Depth of Teeth The maximum depth to which a tooth penetrates into the tooth space of the
mating gear is the working depth of teeth.
 Working depth = Sum of addendums of the two gears.
13. Working depth. It is the radial distance from the addendum circle to the clearance circle.
It is equal to the sum of the addendum of the two meshing gears.
14. Tooth thickness. It is the width of the tooth measured along the pitch circle.
15. Tooth space. It is the width of space between the two adjacent teeth measured along the pitch circle.
16. Backlash. It is the difference between the tooth space and the tooth thickness, as measured along the
pitch circle. Theoretically, the backlash should be zero, but in actual practice, some backlash must be
allowed to prevent jamming of the teeth due to tooth errors and thermal expansion.
17. The face of a tooth. It is the surface of the gear tooth above the pitch surface.
18. The flank of the tooth. It is the surface of the gear tooth below the pitch surface.
19. Top land. It is the surface of the top of the tooth.
20. Face width. It is the width of the gear tooth measured parallel to its axis.
21. Fillet It is the curved portion of the tooth flank at the root circle.
22. Circular pitch. It is the distance measured on the circumference of the pitch circle from point of one
tooth to the corresponding point on the next tooth.
It is usually denoted by pc .
Mathematically,
d
Circular pitch, pc 
T
Where d= Diameter of the pitch circle, and
T = Number of teeth on the wheel.
The angle subtended by the circular pitch at the center of the pitch circle is known as the pitch angle.

23. Module (m). It is the ratio of the pitch diameter in mm to the number of teeth.
d
m
T
d
Also pc   m
T
 Pitch of two mating gear must be the same.
24. Diametral Pitch (P)It is the number of teeth per unit length of the pitch circle diameter in inch.
OR
It is the ratio of no. of teeth to pitch circle diameter in inch.
T
Pd 
d
 The recommended series of modules in Indian Standard are 1, 1.25, 1.5, 2, 2.5, 3, 4, 5, 6, 8, 10, 12,
16, and 20. The modules 1.125, 1.375, 1.75, 2.25, 2.75, 3.5, 4.5, 5.5, 7, 9, 11, 14 and 18 are of second
choice.
25. Gear Ratio (G). It is the ratio of the number of teeth on the gear to that on the pinion.
T
G Where T= No of teeth on a gear
t
t = No. of teeth on the pinion
26. Velocity Ratio (VR) The velocity ratio is defined as the ratio of the angular velocity of the follower to
the angular velocity of the driving gear.
2 N2 d1 T1
VR    
1 N1 d2 T2
27. Length of the path of contact. It is the length of the common normal cut-off by the
Addendum circles of the wheel and pinion.
OR
The locus of the point of contact of two mating teeth from the beginning of the engagement to the end of
engagement is known as the contact.
a. Path of Approach Portion of the path of contact from the beginning of the engagement to
the pitch point.
b. Path of Recess Portion of the path of contact from the pitch point to the end of the
engagement.
28. Arc of Contact The locus of a point on the pitch circle from the beginning to the end of the engagement
of two mating gears is known as the arc of contact.
a. Arc of Approach It is the portion of the arc of contact from the beginning of the engagement
to the pitch point.
b. Arc of Recess The portion of the arc of contact from the pitch point to the end of
engagements the arc of recess.
29. The angle of Action (𝜹) It is the angle turned by gear from the beginning of the engagement to the end
of engagement of a pair of teeth, i.e., the angle turned by arcs of contact of respective gear wheels.
     Where  =Angle of approach
 =Angle of recess
30. Contact ratio. It is the angle of action divided by the pitch angle
  
Contact ratio  
 
OR
Arcof contact
Contact ratio 
Circularpitch
7.2.1 Condition for Constant Velocity Ratio of Toothed Wheels – Law of Gearing
To understand the theory consider the portions of two gear teeth gear 1 and gear 2. The two teeth come
in contact at point C and the direction of rotation of gear 1 is anticlockwise & gear 2 is clockwise.
Let TT be the common tangent & NN be the common normal to the curve at the point of contact C. From
points O, & O2, draw O1A & O2B perpendicular to common normal NN. When the point D is considered on
gear 1, the point C moves in the direction of “CD” & when it is considered on gear 2. The point C moves in
the direction of “CE”.
Fig.7.11 – Law of gearing

The relative motion between tooth surfaces along the common normal NN must be equal to zero in order
to avoid separation. So, relative velocity
𝑉1 cos 𝛼 = 𝑉2 cos 𝜃
(ω1 × 𝑂1 𝐶) cos 𝛼 = (ω2 × 𝑂2 𝐶) cos 𝜃 (∵ 𝑉 = 𝑟 𝜔) Eq. (7.1)
O1 A
But from  O1 AC, cos  
O1 C
O2 B
and from  O2 BC, cos  
O2 C

Putting the above value in Eq. (7.1) it becomes
𝑂1 𝐴 𝑂2 𝐵
(ω1 × 𝑂1 𝐶) = (ω2 × 𝑂2 𝐶)
𝑂1 𝐶 𝑂2 𝐶
∴ (ω1 × 𝑂1 𝐴) = (ω2 × 𝑂2 𝐵)
ω1 𝑂2 𝐵 Eq. (7.2)
∴ =
ω2 𝑂2 𝐴
From a similar triangle  O1 AP &  O2 BP

𝑂2 𝐵 𝑂2 𝑃 Eq. (7.3)
=
𝑂2 𝐴 𝑂2 𝑃
Equating Eq. (7.2) and Eq. (7.3)
1 O2 B O P PB
  2 
2 O1 A O1 P AP
From the above, we can conclude that the angular velocity ratio is inversely proportional to the ratio of the
distances of the point P from the central O1& O2.
If it is desired that the angular velocities of two gear remain constant, the common normal at the point of
contact of two teeth always passes through a fixed point P. This fundamental condition is called as law
of gearing which must be satisfied while designing the profiles of teeth for gears.
7.2.2 Standard Tooth Profiles or Systems

Following four types of tooth profiles or systems are commonly used in practice for interchangeability:
1
a) 14 composite system
2
1
b) 14 full depth involute system
2
c) 20 full depth involute system
d) 20 stub involute system
1
a) 14 composite system:
2
This type of profile is made with circular arcs at the top and bottom portion and the middle portion is a
straight line. The straight portion corresponds to the involute profile and the circular arc portion
corresponds to the cycloidal profile. Such profiles are used for general purpose gears.
1
Fig.7.12 - 14 composite system
2

1
b) 14 full depth involute system:
2
1
Fig.7.13 - 14 full depth involute system
2
This type of profile is made straight line except for the fillet arcs. The whole profile corresponds to the
involute profile. Therefore manufacturing of such profiles is easy but they have interface problems.
c) 20 full depth involute system:
Fig.7.14 - 20 full depth involute system
1
This type of profile is the same as 14 the full depth involute system except for the pressure angle. The
2
1
increase of pressure angle from 14 to 20 results in a stronger tooth, since the tooth acting like a beam,
2
is wider at the base. This type of gears also has an interference problem if the number of teeth is less.
d) 20 stub involute system:
Fig.7.15 - 20 stub involute system

The problem of interference in 20 full depth involute system is minimized by removing extra addendum
of gear tooth which causes interference. Such a modified tooth profile is called “Stub tooth profile”. This
type of gears is used for heavy load.
7.3 Length of Path of Contact And Length of Arc of Contact
7.3.1 Length of Path of Contact
Fig.7.16 - Length of Path of Contact
 When the pinion rotates in the clockwise direction, the contact between a pair of involute teeth
begins at K (on the flank near the base circle of pinion or the outer end of the tooth face on the
wheel) and ends at L (on the flank near the base circle of the wheel).
 MN is the common normal at the point of contact and the common tangent to the base circles.
 The point K is the intersection of the addendum circle of the wheel and the common tangent.
 The point L is the intersection of the addendum circle of pinion and common tangent.
 The length of the path of contact is the length of the common normal cutoff by the addendum
circles of the wheel and the pinion.
 Thus the length of the path of contact is KL which is the sum of the parts of the path of contacts
KP and PL. The part of the path of contact KP is known as the path of approach and the part of the
path of contact PL is known as the path of recess.
L.P.C  KL
 KP  PL
where, KP = path of approach
PL = path of recess

Let,
R = O2P = pitch circle radius of wheel
RA = O2K = addendum circleradius of wheel
r = O1P = pitch circle radius of pinion
rA = O1L = addendumcircleradius of pinion
Length of the path of contact = Path of approach + path of recess
= KP  PL
 KN  PN  ML  MP 
  O2K2  O2N2  PN    O1L2  O1M2  MP 

 R A
2
 Rcos ø   Rsin ø 
2
 rA2  rcos ø   rsin ø
2

7.3.2 Length of Arc of Contact
 The arc of contact is the path traced by a point on the pitch circle from the beginning to the end of
the engagement of a given pair of teeth.
 The arc of contact is EPF or GPH.
 Considering the arc of contact GPH, it is divided into two parts i.e. arc GP and arc PH. The arc GP
is known as arc of approach and the arc PH is called the arc of recess.
 The angles subtended by these arcs at O1 are called angle of approach and angle of recess
respectively.
Length of the arc of contact GPH   GP  PH 
 Arc of approach  Arc of recess

KP PL
 
cos ø cos ø
KP  PL KL
 
coscos ø cos ø
Length of path of contact

cos ø
7.3.3 Contact Ratio (or Number of Pairs of Teeth in Contact)

The contact ratio or the number of pairs of teeth in contact is defined as the ratio of the length of the arc
of contact to the circular pitch.
Mathematically, Contact ratio or number of pairs of teeth in contact
Length of arc of contact


Circular pitch

πm

Notes:
 For continuous transmission of the motion, at least one tooth of anyone wheel must be in contact
with another tooth of the second wheel so ‘n’ must be greater than unity.
 If ‘n’ lies between 1& 2, no. of teeth in contact at any time will not be less than one and will never
mate two.
 If ‘n’ lies between 2 & 3, it is never less than two pairs of teeth and not more than three pairs and
so on.
 If ‘n’ is 1.6, one pair of teeth are always in contact whereas two pair of teeth are in contact for 60%
of the time.
7.4 Interference in Involute Gears
Fig.7.17 - Interference in involute gears
 A pinion with centerO1, in mesh with wheel or gear with centreO2. MN is the common tangent to
the base circles and KL is the path of contact between the two mating teeth.
 A little consideration will show that if the radius of the addendum circle of pinion is increased to
O1N, the point of contact L will move from L to N. When this radius is further increased, the point
of contact L will be on the inside of base circle of wheel and not on the involute profile of tooth on
wheel. The tip of the tooth on the pinion will then undercut the tooth on the wheel at the root and
remove part of the involute profile of the tooth on the wheel. This effect is known as interference
and occurs when the teeth are being cut. In brief, the phenomenon when the tip of the tooth
undercuts the root on its mating gear is known as interference.
 Similarly, if the radius of the addendum circles of the wheel increases beyond O2M, then the tip of
the tooth on the wheel will cause interference with the tooth on pinion.
 The points M and N are called interference points. Interference may be avoided if the path of
contact does not extend beyond interference points. The limiting value of the radius of the
addendum circle of the pinion is O1N and the wheel is O2M.

7.4.1 How to avoid interference?
 The interference may only be avoided if the point of contact between the two teeth is always on
the involute profiles of both the teeth.
OR
 Interference may only be prevented if the addendum circles of the two mating gears cut the
common tangent to the base circles between the points of tangency.
When interference is just avoided, the maximum length of the path of contact is MN.
The maximum length of the path of contact  MN
 MP  PN
 r sinø  R sinø
  r  R  sinø
The maximum length of the arc of contact 

r  R  sinø
cosø
Notes:
In case the addenda on pinion and wheel are such that the path of approach and path of recess are
half of their maximum possible values, then
1
Path of approach, KP = MP
2
 1

RA2  Rcos ø   Rsin ø  rsinø
2
2
1
Path of recess, PL  PN
2
 
1
rA2  rcos ø   rsin ø  Rsinø
2
2
Length of the path of contact KP  PL
1 1
 MP  PN
2 2

 r  R  sinø
2
7.4.2 Minimum Number of Teeth on the Pinion in Order to Avoid Interference

 In order to avoid interference, the addendum circles for the two mating gears must cut the common
tangent to the base circles between the points of tangency.
 The limiting condition reaches when the addendum circles of pinion and wheel pass-through point
N and M respectively.
Let t = Number of teeth on the pinion,
T = Number of teeth on the wheel,
m = Module of the teeth,
r = Pitch circle radius of pinion = mt/ 2
G = Gear ratio = T / t = R / r
ø = Pressure angle or angle of obliquity.
From ∆ O1NP,
O1N 2  O1P 2  PN2  2OP  PNcos O1PN 
O1N 2  r2  Rsinø   2r Rsinø   cos  90  ø 

2
O1N 2  r2  Rsinø   2r Rsinø   cos  90  ø 

2
O1N2  r2  R2 sin2 ø  2rRsin2 ø
 R2 sin2 ø 2Rsin2 ø 
O1N2  r2 1   
 r2 r 
 R2 sin2 ø 2Rsin2 ø 
O1N2  r2 1   
 r2 r 
 RR  
O1N2  r2 1    2  sin2 ø 
 rr  
RR 
O1N  r 1    2  sin2 ø
rr 
mt RR 
O1N  1    2  sin2 ø
2 rr 
Let Ap  m = Addendum of the pinion, where AP is a fraction by which the standard addendum of
one module for the pinion should be multiplied in order to avoid interference.
Addendum of the pinion  O1N– O1P
mt TT  mt
AP .m  1    2  sin2 ø 
2 tt  2
mt TT  mt
 AP .m  1    2  sin2 ø 
2 tt  2
mt  T T  2 
 AP .m   1    2  sin ø  1
2  tt  
mt  T T  2 
 AP .m   1    2  sin ø  1
2  tt  
t TT  
 AP .   1    2  sin2 ø  1
2  tt  

t TT  
 AP   1    2  sin2 ø  1
2  tt  
t TT  
 AP   1    2  sin2 ø  1
2  tt  
2 AP
t 
 TT  2 
 1    2  sin ø  1
 tt  
2AP
t 
 1  G  G  2  sin2 ø  1
 
Note:
If the pinion and wheel have equal teeth, then G = 1.
2AP
t 
 1  3sin2 ø  1
 
Table 7.1 - Min. no of teeth on pinion
Sr. No. System of Gear Tooth Min. no. of teeth on the pinion
1
1 14 ° Composite 12
2
1
2 14 2 °Full depth involute 32
3 20° Full-depth involute 18
4 20°Stub involute 14
7.4.3 Minimum Number of Teeth on the Wheel in Order to Avoid Interference

Let T = Minimum number of teeth required on the wheel in order to avoid interference,
Aw  m = Addendum of the wheel, where AW is a fraction by which the standard
The addendum for the wheel should be multiplied.

From ∆O2MP
O2M2  O2P2  PM2  2O2P  PMcos  O2PM
O2M2  R2  rsinø   2r Rsinø   cos  90  ø 

2
O2M2  R2  r2 sin2 ø  2rRsin2 ø
 r2 sin2 ø 2rsin2 ø 
O2M2  R2 1  
 R2 R 

 rr  
O2M2  R2 1    2  sin2 ø 
 RR  
rr 
O2M  R 1    2  sin2 ø
RR 
mT rr 
O2M  1    2  sin2 ø
2 RR 
Addendum of the wheel  O2M – O2P
mT tt  mT
Aw m  1    2  sin2 ø 
2 TT  2
mT  tt  2 
 Aw m   1    2  sin ø  1
2  TT  
mT  tt  2 
 Aw m   1    2  sin ø  1
2  TT  
T tt  
 Aw   1    2  sin2 ø  1
2  TT  
2 Aw
T 
 tt  2 
 1    2  sin ø  1
 TT  
2Aw
T 
 11  2 
 1    2  sin ø  1
 G G  
Note:
From the above equation, we may also obtain the minimum number of teeth on the pinion. Multiplying
both sides by t/T,
t
2 Aw 
t T
T 
T  11  2 
 1    2  sin ø  1
 G G  
2 Aw
t 
 11  
G  1    2  sin2 ø  1
 G G  
If wheel and pinion have equal teeth, then G = 1,
2Aw
T 
 1  3sin2 ø  1
 
7.4.4 Minimum Number of Teeth on a Pinion for Involute Rack in Order to Avoid Interference
Fig.7.18 - Rack, and pinion in mesh
Let t = Minimum number of teeth on the pinion,

m t
r = Pitch circle radius of the pinion = and
2
ø= Pressure angle or angle of obliquity, and
AR  m = Addendum for the rack, where AR is the fraction by which the standard addendum of one
module for the rack is to be multiplied.
Addendum for the rack, AR  m  LH
 AR  m  PL sin 
 AR  m  r sin φ  sin φ
 AR  m  r sin2φ
mt sin2φ
 AR  m 
2
2A
t  2 R
sin φ
Note:
In the case of pinion, max. value of addendum radius to avoid interference if AF
 O2M2  AF2
 rcos ø   Rsinø  rsinø 

2 2
Max value of addendum of the pinion is

RR 
A 
p max  r 1    2  sin2 ø  1
rr 
mt 
 1  G  G  2  sin2 ø  1
2  

7.5 Comparison of Cycloidal and Involute tooth forms
Table 7.2 - Comparison of Cycloidal and Involute tooth forms
Cycloidal teeth Involute teeth
Pressure angle varies from a maximum at the The pressure angle is constant throughout the
beginning of the engagement, reduces to zero engagement of teeth. This results in the
at the pitch point and again increases to a smooth running of the gears.
maximum at the end of the engagement
resulting in the smooth running of gears.
It involves double curves for the teeth, It involves the single curves for the teeth
epicycloid, and hypocycloid. This complicates resulting in simplicity of manufacturing and of
the manufacturer. tool
Owing to the difficulty of the manufacturer, These are simple to manufacture and thus are
these are costlier. cheaper.
Exact center distance is required to transmit a A little variation in a center distance does not
constant velocity ratio. affect the velocity ratio.
The phenomenon of interference does not Interference can occur if the condition of
occur at all. minimum no. of teeth on a gear is not followed.
The teeth have spreading flanks and thus are The teeth have radial flanks and thus are
stronger. weaker as compared to the Cycloidal form for
the same pitch.
In this, a convex flank always has contact with Two convex surfaces are in contact and thus
a concave face resulting in less wear. there is more wear.
7.6 Helical and Spiral Gears
Fig.7.19 – Helical Gear
 A helical gear has teeth in the form of the helix around the gear. Two such gears may be used to
connect two parallel shafts in place of the spur gear. The helixes may be right-handed on one wheel
and left-handed on the other.
 The pitch surfaces are cylindrical as in spur gearing, but the teeth instead of being parallel to the
axis, wind around the cylinders helically like screw threads.
 The teeth of helical gears with parallel axis have line contact, as in spur gearing. This provides
gradual engagement and continuous contact of the engaging teeth. Hence helical gears give
smooth drive with high efficiency of transmission.
 The helical gears may be of the single helical type or double helical type. In the case of single
helical gears, there is some axial thrust between the teeth, which is a disadvantage.
 In order to eliminate this axial thrust, double helical gears are used. It is equivalent to two single
helical gears, in which equal and opposite thrusts are produced on each gear and the resulting axial
thrust is zero.
 The following definitions may be clearly understood in connection with a helical gear:
1. Normal pitch. It is the distance between similar faces of adjacent teeth, along a helix on the pitch
cylinder normal to the teeth. It is denoted by pN.
2. Axial pitch. It is the distance measured parallel to the axis, between similar faces of adjacent
teeth. It is the same as circular pitch and is therefore denoted by pc. If α is the helix angle, then
pN
Circular pitch, pc 
Cos
Note: The helix angle is also known as the spiral angle of the teeth.
7.6.1 The efficiency of Spiral Gears

A pair of spiral gears 1 and 2 are in mesh. Let the gear 1 be the driver and the gear 2 the driven. The forces
acting on each of a pair of teeth in contact. The forces are assumed to act at the center of the width of
each teeth and in the plane tangential to the pitch cylinders
Fig.7.20 - Efficiency of Spiral Gears

Let F1 = Force applied tangentially on the driver,
F2 = Resisting force acting tangentially on the driven,
Fa1 = Axial or end thrust on the driver,
Fa2 = Axial or end thrust on the driven,
RN = Normal reaction at the point of contact
 = Angle of friction,
R = Resultant reaction at the point of contact, and
 = Shaft angle =1 +2
...( Both gears are of the same hand)
From triangle OPQ, F1 = R cos  1   
 Work input to the driver = F1  d1  N1  Rcos  1     d1  N1
From triangle OST, F2  Rcos(2  )
 Work output of the driven = F2  d2  N2  Rcos   2     d2  N2
Efficiency of spiral gears,
Work output Rcos  2     d2  N2

 
Work input Rcos  1     d1  N1
cos  2     d2  N2

cos  1     d1  N1
Pitch circle diameter of gear 1,

pc1  T1 pN T
d1    1
 Cos1 
Pitch circle diameter of gear 2,

pc2  T2 pN T
d2    2
 Cos2 
d2 T2Cos1
  (2)
d1 T1Cos2
N2 T1
 (3)
N1 T2
Multiplying equation (2) and (3) we get

d2N2 cos 1

d1N1 cos 2
Substituting this value in equation (1)
cos  2    cos 1
 (4)
cos  1    cos 2

cos  1  2     cos  1  2   

cos  1  2     cos  1  2   
 1 
 cos A  cosB  cos  A  B   cos  A  B   
 2 
cos       cos  1   2   
 (5)
cos       cos  1   2   
   1   2 
Since the angle  and  are constants, therefore the efficiency will be maximum, when cos  1  2   
is maximum, i.e. cos  1  2    =1
1  2    0
1  2   and 2  1  
Since 1  2   therefore

1    2    1   OR 1 
2

Similarly 2 
2
Substituting 1  2   and 2  1   in equation (5) we get
cos       1
max 
cos       1
7.7 Introduction to Gear Trains and Its Classification

When two or more gears are made to mesh with each other to transmit power from one shaft to another.
Such a combination is called gear train or train of toothed wheels.
The nature of the train used depends upon the velocity ratio required and the relative position of the axes
of shafts. A gear train may consist of a spur, bevel or spiral gears.
Types of Gear Trains
1. Simple gear train
2. Compound gear train
3. Reverted gear train
4. Epicyclic gear train
5. Compound epicyclic gear train
7.7.1 Simple gear train

When there is only one gear on each shaft, it is known as a simple gear train. The gears are represented
by their pitch circles. When the distance between the two shafts is small, the two gears 1 and 2 are made
to mesh with each other to transmit motion from one shaft to the other. Since the gear 1 drives the gear
2, therefore gear 1 is called the driver and the gear 2 is called the driven or follower. It may be noted that
the motion of the driven gear is opposite to the motion of driving gear.

Fig.7.21 - Simple gear train
Let,
N1  Speedof driver rpm
N2  Speedofintermediatewheel rpm
N3  Speedof follower rpm
T1  Number of teethon driver
T2  Number of teethonintermediatewheel
T3  Number of teethonfollower
Since the driving gear, 1 is in mesh with the intermediate gear 2, so speed ratio for these two gears is
N1 T2
 (1)
N2 T1
As the intermediate gear, 2 is in mesh with the driven gear 3, so speed ratio for these two gears is
N2 T3
 (2)
N3 T2
The speed ratio of the gear train is obtained by multiplying the equations (1) and (2).
N1 N2 T2 T3
  
N2 N3 T1 T2
N T
 1 3
N3 T1
Sometimes, the distance between the two gears is large. The motion from one gear to another, in such a
case, maybe transmitted by either of the following two methods:
1. By providing the large-sized gear, or
 A little consideration will show that this method (i.e. providing large-sized gears) is a very
inconvenient and uneconomical method.
2. By providing one or more intermediate gears.
 This method (i.e. providing one or more intermediate gear) is very convenient and economical.
It may be noted that when the number of intermediate gears is odd, the motion of both the gears (i.e. driver
and driven or follower) will rotate in the same direction.
If the numbers of intermediate gears are even, the motion of the driven or follower will be in the opposite
direction of the driver.
 Speed ratio (or velocity ratio) of the gear train is the ratio of the speed of the driver to the speed of the
driven or follower and the ratio of speeds of any pair of gears in the mesh is the inverse of their number
of teeth.
N1 T2
Speedratio  
N2 T1

 The train value of the gear train is the ratio of the speed of the driven or follower to the speed of the
driver.
N2 T1
Trainvalue  
N1 T2
7.7.2 Compound Gear Train

When there is more than one gear on a shaft, it is called a compound train of gear.
Fig.7.22 - Compound Gear Train

The idle gears, in a simple train of gears, do not affect the speed ratio of the system. But these gears are
useful in bridging over the space between the driver and the driven.
But whenever the distance between the driver and the driven or follower has to be bridged over by
intermediate gears and at the same time a great (or much less) speed ratio is required, then the advantage
of intermediate gears is intensified by providing compound gears on intermediate shafts.
In this case, each intermediate shaft has two gears rigidly fixed to it so that they may have the same speed.
One of these two gears meshes with the driver and the other with the driven or follower attached to the
next shaft.
In a compound train of gears, the gear 1 is the driving gear mounted on shaft A; gears 2 and 3 are
compound gears which are mounted on shaft B. The gears 4 and 5 are also compound gears which are
mounted on shaft C and the gear 6 is the driven gear mounted on shaft D.
Let,
N1 = Speed of driving gear 1,
T1 = Number of teeth on driving gear 1,
N2 ,N3 ..., N6 = Speed of respective gears in r.p.m., and
T2 ,T3..., T6 = Number of teeth on respective gears.
Since gear 1 is in mesh with gear 2, therefore its speed ratio is
N1 T2
 (1)
N2 T1
Similarly, for gears 3 and 4, the speed ratio is
N3 T4
 (2)
N4 T3

And for gears 5 and 6, speed ratio is
N5 T6
 (3)
N6 T5
The speed ratio of the compound gear train is obtained by multiplying the equations (1), (2) and (3),
N1 N3 N5 T2 T4 T6
    
N2 N4 N6 T1 T3 T5
The advantage of a compound train over a simple gear train is that a much larger speed reduction from
the first shaft to the last shaft can be obtained with small gears. If a simple gear train is used to give a
large speed reduction, the last gear has to be very large. Usually, for a speed reduction in excess of 7 to 1,
a simple train is not used and a compound train or worm gearing is employed.
7.7.3 Reverted Gear Train
Fig.7.23 - Reverted Gear Train

When the axes of the first gear (i.e. first driver) and the last gear (i.e. last driven or follower) are co-axial,
then the gear train is known as a reverted gear train.
Gear 1 (i.e. first driver) drives the gear 2 (i.e. first driven or follower) in the opposite direction. Since the
gears 2 and 3 are mounted on the same shaft, therefore they form a compound gear and the gear 3 will
rotate in the same direction as that of gear 2.
The gear 3 (which is now the second driver) drives the gear 4 (i.e. the last driven or follower) in the same
direction as that of gear 1. Thus we see that in a reverted gear train, the motion of the first gear and the
last gear is like.
Let,
T1  Number of teeth on gear 1,
r1  Pitch circle radius of gear 1, and
N1  Speed of gear 1 in r.p.m.
Similarly,
T2, T3, T4  Number of teeth on respective gears,
r2, r3, r4  Pitch circle radii of respective gears, and
N2, N3, N4  Speed of respective gears in r.p.m.

Since the distance between the centers of the shafts of gears 1 and 2 as well as gears 3 and 4 is the same,
therefore
r1  r2  r3  r4
Also, the circular pitch or module of all the gears is assumed to be the same; therefore the number of teeth
on each gear is directly proportional to its circumference or radius.
T1  T2  T3  T4
Product of number of teeth on drivens
Speedratio 
Product of number of teeth on drivers
N1 T2  T4

N4 T1  T3
Applications:
The reverted gear trains are used in automotive transmissions, lathe back gears, industrial speed reducers,
and in clocks (where the minute and hour hand shafts are co-axial).
7.7.4 Epicyclic Gear Train
Fig.7.24 - Epicyclic Gear Train

In an epicyclic gear train, the axes of the shafts, over which the gears are mounted, may move relative to
a fixed axis. A gear A and the arm C have a common axis at O1 about which they can rotate. The gear B
meshes with gear A and has its axis on the arm at O2, about which the gear B can rotate.
If the arm is fixed, the gear train is simple and gear A can drive gear B or vice- versa, but if gear A is fixed
and the arm is rotated about the axis of gear A (i.e. O1), then the gear B is forced to rotate upon and around
gear A.
Such a motion is called epicyclic and the gear trains arranged in such a manner that one or more of their
members move upon and around another member is known as epicyclic gear trains (epi. means upon and
cyclic means around). The epicyclic gear trains may be simple or compound.
Applications:
The epicyclic gear trains are useful for transmitting high-velocity ratios with gears of moderate size in a
comparatively lesser space. The epicyclic gear trains are used in the back gear of lathe, differential gears
of the automobiles, hoists, pulley blocks, wristwatches, etc.

Table 7.3 - Table of Motions
Step Revolution of Elements

Condition of Motion
No. Arm C Gear A Gear B
TA
1 Arm fixed - gear A rotates +1 revolution (anticlockwise) 0 +1 
TB
TA
2 Arm fixed - gear A rotates through + x revolutions 0 x x
TB
3 Add + y revolutions to all elements y y y
TA
4 Total motion y x y y- x
TB
Applications:
The epicyclic gear trains are useful for transmitting high-velocity ratios with gears of moderate size in a
comparatively lesser space. The epicyclic gear trains are used in the back gear of lathe, differential gears
of the automobiles, hoists, pulley blocks, wristwatches, etc.
7.7.5 Compound Epicyclic Gear Train—Sun and Planet Gear

A compound epicyclic gear train consists of two co-axial shafts S1 and S2, an annulus gear A which is
fixed, the compound gear (or planet gear) B-C, the sun gear D, and the arm H. The annulus gear has internal
teeth and the compound gear is carried by the arm and revolves freely on a pin of the arm H. The sun gear
is co-axial with the annulus gear and the arm but independent of them.
The annulus gear A meshes with the gear B and the sun gear D meshes with the gear C. It may be noted
that when the annulus gear is fixed, the sun gear provides the drive and when the sun gear is fixed, the
annulus gear provides the drive. In both cases, the arm acts as a follower.
Note: The gear at the center is called the sun gear and the gears whose axes move are called planet gears.
Let TA, TB, TC, and TD be the teeth and NA, NB, NC, and ND be the speeds for the gears A, B, C, and D
respectively. A little consideration will show that when the arm is fixed and the sun gear D is turned
anticlockwise, then the compound gear B-C and the annulus gear A will rotate in the clockwise direction.
Table 7.4 - Table of motions
Revolution of Elements
Step
Conditions of motion Gear Compound Gear
No. Arm Gear A
D (B-C)
Arm fixe, gear D rotates +1 revolution TD TD TB

1 0 +1   
(anticlockwise) TC TC TA
Arm fixed gear D rotates through + x TD TD TB

2 0 +x x x 
revolutions TC TC TA
3 Add + y revolutions to all elements +y +y +y +y
TD TD TB
4 Total motion +y xy yx yx 
TC TC TA

7.8 Problems
Ex. 7.1 Two spur gears have a velocity ratio of 1/3 the driven gear has 72 teeth of 8 mm module
and rotates at 300 RPM. Calculate the number of teeth and Speed of driver. What will be
the pitch line velocity?
Solution: Given data Find
VR  1 / 3 Vp  ?
T2  72 teeth T1  ?
m  8 mm
N2  300
N2 T1
VR  
N1 T2
1 300 T1
  
3 N1 72
 T1  24 &N1  900 rpm
Pitch line velocity,
VP  r11  r22
2N1 d1
 
60 2
2N1 mT1
 
60 2
2 900 8  24
 
60 2
 9047.78 mm / sec
Ex. 7.2 The number of teeth of spur gear is 30 and it rotates at 200 RPM. What will be its circular
pitch and the pitch line velocity if it has a module of 2 mm?
Solution: Given data Find:
T  30 Pc  ?
N  200 rpm Vp  ?
m  2 mm
Circular pitch, Pc   m
  2
 6.28mm

Pitch line velocity, Vp   r
2N d
 
60 2
2 200 2  30
 
60 2
 628.3mm / s
Ex. 7.3 The following data relate to two meshing gears velocity ratio = 1/3, module = 1mm,
Pressure angle 20°, center distance= 200 mm. Determine the number of teeth and the
base circle radius of the gear wheel.
VR  1 / 3 T1  ?
Ø  20 T2  ?
C  200 mm Base circle radius of gear wheel  ?
m  4 mm
N 2 1 T1
VR   
N1 3 T2
T2  3T1 (1)
d1  d 2
Center distance C 
2
m T1  T2   d
 200   m 
2  2
4 T1  T2 
 200 
2
T1  T2  100 (2)
By solving equation (1) & (2)
T1  25
T2  75
No of teeth of the gear wheel T2  75
d2
But m 
T2
d2  mT2
d2  300mm
d2
Base circle radius db2  cos 
2
300
  cos20
2
 141mm

Ex. 7.4 Each of the gears in a mesh has 48 teeth and a module of 8 mm. The teeth are of a 20°
involute profile. The arc of' contact is 2.25 times the circular pitch. Determine the
addendum.
T  t  48 Addendum  ?
m  8 mm
ø  20
Arc of contact  2.25 Pc
Arc of contact  2.25Pc
 2.25m
 2.25 8
 56.55mm
d 2r
Let, m  
t T
mT 8  48
R  r  
2 2
R  r  192mm
Also, Ra  ra ( toothsizesame)
L.P.C
L.A.C 
COS
L.P.C
 56.55 
COS20
 L.P.C  53.14 mm
L.P.C  R A
2
r
 Rcosø   Rsinø 
2
A
2
 rcosø   rsinø
2

53.14  2  RA2  Rcoscosø    R+r  sinø  RA  rA 
2
 
53.14  2  RA2  192cos20    192  192  sin20

2
 
 53.14  2  RA2  32551.73   131.33

 
 RA2  32551.73  92.23mm

RA  202.63mm
Now RA  R  Addendum
Addendum  RA  R
 Addendum  10.63mm

Ex. 7.5 Two involute gears in mesh have a 20° pressure angle. The gear ratio is 3 and the number
of teeth on the pinion is 24. The teeth have a module of 6 mm. The pitch line velocity is
1.5 m/s and the addendum equal to one module. Determine the angle of action of a pinion
(the angle turned by the pinion when one pair of teeth is in the mesh) and the maximum
velocity of sliding.
Ø  20 Angle of action of the pinion  ?
G  T/t  3 Max. velocity of sliding  ?
t  24
m  6 mm
Vp  1.5 m / s
Addendum  1 module
mt 6  24 mT 6  72
r   72mm R   216mm
2 2 2 2
 T  24  3  72 
ra  r  Add.  72  (1  6)  78mm RA  R  Add.  216  (1  6)  222mm
Let the length of the path of contact KL  KP  PL
KP  R A
2
 Rcosø   Rsinø
2

 
  2222   216cos20 
2
 216sin20 
 
 16.04mm
PL  rA
2
2

 
  782   72cos20 
2
 72 sin20 
 
 14.18mm
Pathof contact
Arcof contact 
cos
16.04  14.18

cos20
 32.16mm
Lengthof arcof contact  360
Angleturnedthroughbypinion( ) 
circumferenceofpinion
32.16  360

2 72
 25.59
Max.velocityof sliding  (p  g )  KP
V V
     KP  V  r
r R
 1500 1500 
    16.04
 72 216 
 445.6mm / sec
Ex. 7.6 Two involute gears in a mesh have a module of 8 mm and a pressure angle of 20°. The
larger gear has 57 while the pinion has 23 teeth. If the addendum on pinion and gear
wheels are equal to one module, Determine
i. Contact ratio (No. of pairs of teeth in contact )
ii. The angle of action of pinion and gear wheel
iii. The ratio of sliding to the rolling velocity at the
a. Beginning of the contact.
b. Pitch point.
c. End of the contact.

Ø  20 1. Contact ratio  ?
m  8 mm 2. Angle of action of pinion and gear  ?
T  57 3. Ratio of sliding to rolling velocity at the
t  23 a. Beginning of contact
Addendum  1 module b. Pitch point
 8 mm c. End of contact
i. Let the length of the path of contact KL = KP +PL
KP = R A
2
- Rcosø  - Rsinø
2

 
=  2362 -  228cos20o  - 228sin20o 
2
 
= 20.97 mm
PL =  rA 2 -  rcosø  - rsinø
2

 
  1002   92cos20 
2
 92sin20 
 
= 18.79mm
Pathof contact
Arcof contact 
cos
KP  KP

cos
20.97  18.79

cos20
 42.29mm
Lengthof arcof contact
Contactratio 
Pc
42.21
  1.68 say 2
m
ii.
Angleof actionofpinion(p ) 
circumferenceofpinion
42.31  360

2 92
 26.34
Angleof actionofpinion(g ) 
circumferenceof gear
42.31  360

2 228
 10.63
iii. The ratio of sliding to rolling velocity:
a. Beginning of contact
Slidingvelocity  p  g KP

Rollingvelocity pr
 92 
 p  P   20.97

228 
p  92
 0.32
b. Pitch point
Slidingvelocity  p  g KP



p  g   0
pr
0
c. End of the contact
Slidingvelocity  p  g PL

 92 
 p  P   18.79

228 
p  92
 0.287
Ex. 7.7 Two 20° gears have a module pitch of 4 mm. The number of teeth on gears 1 and 2 is 40
and 24 respectively. If the gear 2 rotates at 600 rpm, determine the velocity of sliding
when the contact is at the tip of the tooth of gear 2. Take addendum equal to one module.
Also, find the maximum velocity of sliding.

Ø  20 Velocity of sliding  ?
m  4 mm Max. velocity of sliding  ?
Np  600 rpm
T  40
t  24
Addendum  1 module
 4 mm
mt 4  24 mT 4  40
r   48mm R   80mm
2 2 2 2
ra  r  Add.  48  (1  4)  52mm RA  R  Add.  80  (1  4)  84mm
(Note: The tip of the driving wheel is in contact with a tooth of driving wheel at the end of
the engagement. So it is required to find the path of recess.)
Path of recess,
PL  r
A
2
2

 
  522   48cos20 
2
 48sin20 
 
 9.458mm
The velocity of sliding,
 (p  g )  PL
2
  600  360   9.458
60
 Ng t 24 
   Ng  600   360rpm 
 NP T 40 
 956.82mm / sec
Path of recess,
KP  R A
2
2

 
  842   80cos20 
2
 80 sin20 
 
 10.108mm
Max. Velocity of sliding,
  p  g   KP
2
 (600  360)  10.108
60
 1016.16mm / sec
Ex. 7.8 Two 20° involute spur gears mesh externally and give a velocity ratio of 3. The module is
3 mm and the addendum is equal to 1.1 module. If the pinion rotates at the 120 rpm,
determine a minimum no of teeth on each wheel to avoid interference and contact ratio.

Ø  20 tmin & Tmin  ?
VR  3 Contact ratio  ?
m  3
NP  120
Addendum  1.1 module
2A w
I. T
 11  2 
 1    2  sin ø  1
 G G  
2  1.1
T 
 1 1  2 
 1    2  sin 20  1
 3 3  
 T  49.44 teeth
T 51
 T  51teeth And t   17teeth
3 3
II.
mt 3  17 mT 3  51
r   25.5mm R    76.5mm
2 2 2 2
ra  r  Add.  25.5  (1.1  3)  28.8mm RA  R  Add.  76.5  (1.1  3)  28.8mm
Lengthofpathofcontact
Contactratio 
cos   Pc
 R A
2
 Rcosø   Rsinø 
2
r A
2
2

cos20   3
   
 79.8   76.5cos20   76.5sin20    28.82  25.5cos0 
2 2
2
 25.5sin20 
   
cos20   3
 1.78
Thus 1 pair of teeth will always remain in contact whereas, for 78 % of the time, 2 pairs of
teeth will be in contact.
Ex. 7.9 Two involute gears in a mesh have a velocity ratio of 3. The arc of approach is not to be
less than the circular pitch when the pinion is the driver The pressure angle of the involute
teeth is 20°. Determine the least no of teeth on each gear. Also, find the addendum of the
wheel in terms of module.
Ø  20 least no of teeth on the each gear  ?
VR  3 Addendum  ?

Arc of approach = Circular pitch   m
Pathof approach  Arcof approach  cos20
  m  cos20
 2.952m (1)
Let the max lengthofpathof approach  rsin
mt
 sin20
2
 0.171mt (2)
From eq. 1. and 2,
0.171mt  0.2952m
 t  17.26  18 teeth
T  18  3  54 teeth
Max. Addendum of the wheel,
mt  11  2 
A wmax   1    2  Sin   1
2  G G  
m  54  11  2 
  1    2  Sin 20  1
2  3 3  
 1.2m
Ex. 7.10 Two 20° involute spur gears have a module of 10 mm. The addendum is equal to one
module. The larger gear has 40 teeth while the pinion has 20 teeth will the gear interfere
with the pinion?
Ø = 20°
m = 10 mm
Addendum = 1 module
 110
 10mm
To be Calculated: Interference or not?
Let the pinion is the driver,
t = 20 teeth
T = 40 teeth

mt 10  20 mT 10  40
r   100mm R   200mm
2 2 2 2
ra  r  Add.  100  10  110mm RA  R  Add.  200  10  210mm
Pathof approach  R A
2
 R cosø   Rsinø
2

 
  2102   200cos20 
2
 200sin20 
 
 25.29mm
To avoid interference,
Maxlengthofpathof approach  rSin
 100  Sin20
 34.20mm 25.29mm
Therefore, interference will not occur.

Ex. 7.11 Two 20° involute spur gears have a module of 10 mm. The addendum is one module. The
larger gear has 50 teeth and the pinion has l3 teeth. Does interference occur? If it occurs,
to what value should the pressure angle change to eliminate interference?
Ø = 20°
M = 10 mm
Addendum = 1 module = 10 mm
T = 50 and t = 13
To be Calculated: Interference or not?
mt 10  13 mT 10  50
r   65mm R   250mm
2 2 2 2
ra  r  Add.  65  10  75mm RA  R  Add.  250  10  260mm
RCos   RSin  rSin 

2
Ramax 
250Cos20   250Sin20 
2
  65Sin20
 258.45mm
Here actual addendum radius Ra (260 mm) > Ra max value
So interference will occur.
The new value of ø can be found by comparing
Ra max  Ra
Ra  Ra max
RCos   RSin  rSin 
2
Ra 
250Cos   250Sin  65Sin 

2 2
260 
2602   250Cos    250Sin  65Sin 

2 2
Cos2  0.861
  21.88
Note: If pressure angle is increased to 21.88° interference can be avoided.
Ex. 7.12 The following data related to meshing involute gears:
No. of teeth on gear wheel = 60
Pressure angle = 20°
Gear ratio = 1.5
Speed of gear wheel = 100 rpm
Module = 8 mm
The addendum on each wheel is such that the path of approach and path of recess on
each side are 40 % of the maximum possible length each. Determine the addendum for
the pinion and the gear and the length of the arc of contact.
T = 60
Ø = 20°
G = 1.5
Ng = 100 rpm
m = 8 mm
To be Calculated:
Addendum for gear and pinion
Let pinion is the driver.
Max. Possible length of the path of approach  rsin 
 The actual length of the path of approach  0.4 rsin  (Given in data)
Same way, the actual length of the path of the recess  0.4 Rsin  (Given in data)
 0.4 r sin   R A
2
2

 0.4  160sin20  R A
2
 240cos20   240sin20
2

Ra  248.33 mm
 Addendum of wheel  248.3  240  8.3mm

Also,
0.4 Rsin   rA2  rcosø   rsinø
2
 0.4  240  sin20  rA2  160cos20   160sin20

2
ra  173.98  174 mm

 Addendum of pinion  174  160  14 mm
Pathof contact
Length of Arcof contact 
cos

rsin   Rsin    0.4
cos 

160  240   sin20  0.4
cos20
 58.2 mm
Ex. 7.13 A pinion of 20 ° involute teeth rotating at 274 rpm meshes with gear and provides a gear
ratio of 1.8. The no. of teeth on the pinion is 20 and the module is 8 mm. If interference
is just avoided, determine:
1. Addendum on wheel and pinion
2. Path of contact
3. Maximum velocity of sliding on both side of pitch point
Ø  20 1.Addndum on wheel and pinion  ?
m  8 mm 2.Path of contact  ?
Np  275 rpm 3.Max. velocity of sliding onboth side of pitchpoint  ?
T  36
t  20
Max. Addendum on wheel

 11  
 Aw max  R  1    2  sin2 ø  1
 G G  
 1  1  
 Aw max  144  1    2  sin2 20  1
 1.8  1.8  
 11.5 mm
Max. Addendum on pinion
 Ap max  r  1  G G  2  sin2 ø  1
 
 Ap max  80  1  1.8 1.8  2  sin 20  1
2
 
= 27.34 mm
Path of contact when interference is just avoided
 Max. path of approach  Max. path of recess
 rsin   Rsin 
 80sin20  144sin20
 27.36  49.25
 76.6 mm
The velocity of sliding on one side of the approach
 2 275 
 P   28.8 rad / sec 
  p  g  Path of approach 
60

 g 
28.8
 16 rad / sec 
 
 1.8  G 
  28.8  16   27.36
 1225.72 mm / sec
The velocity of sliding on side of the path of recess
  p  g Path of recess
 (28.8  16)  49.25
 2206 mm/ sec

Ex. 7.14 A pinion of 20 involute teeth and 125 mm pitch circle diameter drives a rack. The
addendum of both pinion and rack is 6.25 mm. What is the least pressure angle which
can be used to avoid interference? With this pressure angle, find the length of the arc of
contact and the minimum number of teeth in contact at a time.
T  20 1.Least pressure angle to avoid interference  ?
d  125mm 2. Length of arc of contact  ?
r  OP  62.5mm 3. Min. no. of teeth in contact  ?
Addendum for rack / pinion, LH  6.25mm

Least pressure angle to avoid interference
Let, ø = Least pressure angle to avoid interference
We know that for no interference, rack addendum,
From fig..... LH  PLsin 

 rsin  sin 
 rsin2 
LH 6.25
sin2   
r 62.5
  (18.4349)
Length of the arc of contact
Now, KL  OK2  OL2

 (OP 6.25)2  (rcos )2
 (62.5  6.25)2  (62.5  cos18.439 )2
 34.8 mm
KL 34.8
Length of Arc of Contact    36.68 mm
cos  cos18.439

Min. no. of teeth in contact 
pc

 m
36.68

19.64
 1.87
2
Ex. 7.15 In a spiral gear drive connecting two shafts, the approximate center distance is 400 mm
and the speed ratio = 3. The angle between the two shafts is 50° and the normal pitch is
18 mm. The spiral angles for the driving and driven wheels are equal. Find:
1. Number of teeth on each wheel,
2. Exact center distance,
3. The efficiency of the drive, if friction angle = 6°,
4. Maximum efficiency.
T2
L  400 mm   50 G 3
T1
6 PN  18 mm
1. No. of teeth on a wheel:
PN  T1  1 G 
L   
2  cos 1 cos 2 
PN  T1 1  G
 400  
2 cos 1
 1   2 
 
18  T1 1  3    1   2 
 400  
2 cos25   50  21 
 
 1  25 
 T1  31.64 32
 T2  3T1  96
2. Exact center distance (L):
PN  T1  1 G 
L   
2  cos 1 cos 2 
PN  T1  1  G 
   ( 1   2 )
2  cos 1 
18  32  1  3 

2  cos25 
 404.600 mm
3. The efficiency of drive:
cos  2     cos 1

cos  1     cos 2
cos  1   
 ( 1   2 )
cos  1   
cos  25  6 

cos  25  6 
 90.655 %
4. Maximum efficiency:
cos       1
max 
cos       1
cos  50  6   1

cos  50  6   1
 90.685 %

Ex. 7.16 A drive on a machine tool is to be made by two spiral gear wheels, the spirals of which
are of the same hand and has a normal pitch of 12.5 mm. The wheels are of equal
diameter and the center distance between the axes of the shafts is approximately 134
mm. The angle between the shafts is 80° and the speed ratio 1.25. Determine:
1. the spiral angle of each wheel,
2. The number of teeth on each wheel,
3. The efficiency of the drive, if the friction angle is 6°, and
4. The maximum efficiency.
PN  12.5mm
L  134 mm
G  1.25
  80
1. The spiral angle of each wheel
We know that........
d2 T2Cos1
 
d1 T1Cos2
 T1Cos2  T2Cos1 ( d1  d2 )
T
Cos1  1.25Cos2 ( 1  G  1.25)
T2
Cos1  1.25 Cos(  1 ) ( 1  2  )
Cos1  1.25 Cos(80  1 )
Cos1  1.25  Cos80  Cos1  Sin80  Sin1 
 Cos(A  B)  CosA  CosB  SinA  SinB 
𝐵𝑦 𝑠𝑜𝑙𝑣𝑖𝑛𝑔,
tan𝛼1 = 0.636
∴ 𝛼1 = 32.46∘
𝑎𝑛𝑑 𝛼2 = 80∘ − 32.46∘ = 47.54∘
2. The efficiency of drive:
cos  2     cos 1

cos  1     cos 2
cos  47.24  6   cos32.46

cos  32.46  6   cos47.24
 83 %

3. No. of teeth on the wheel:
d1  d2
L
2
2d
134  1 ( d1  d2 )
2
d1  134 mm
d1 p T
Let pc1   d1  c1 1
T1 
P T
d1  N  1
cos 1 
d  cos 1  
 T1  1
PN
134  cos32.24  
 T1 
12.5
 T1  28.4 30 nos.
T1 T 30
Now, G   1.25  T2  1 
T2 G 1.25
T2  24 nos.
4. Maximum efficiency:
cos       1
max 
cos       1
cos  80  6   1

cos  80  6   1
 83.8 %
Ex. 7.17 The addendum of the teeth is 0.84 module and the power component is 0.95 times the
normal thrust. Find the minimum no. of teeth on the gear wheel and the arc of contact (in
terms of the module) to avoid the interference in the following cases:
I. The gear ratio is unity

II. The gear ratio is 3
III. Pinion gear with a rack
Solution: Here A w  0.84

Cos  0.95    18.19
sin   0.3122

I. Gear ratio is unity
Let, min. no of teeth on gear wheel T
2 Aw
T 
 11  2 
 1    2  sin ø  1
 G G  
2 Aw  G

 G2  1  2G sin2 ø  G
 
2  0.84  1

 12  1  2  (0.3123)2  1
 
 12.73
 T  13 teeth
 t  13 teeth
Length of the arc of contact:
L.P.C   RA2  Rcos ø   Rsin ø 

2
2

 m  t m  13 
 r  2  2  6.5m 
2  rA2  rcos ø   rsin ø
2
 
 rA  r  addendum 
  6.5m  0.84m


 
  7.34m 
 2m  (7.34)  6.5 0.95  (6.5 0.3123)
2 2
 3.876m
3.876m 3.876m
L.A.C  
cos ø 0.95
L.A.C  4.08m
II. Gear ratio G = 3
Let, min. no of teeth on gear wheel T
2 Aw
T 
 11  2 
 1    2  sin ø  1
 G G  
2 Aw  G

 G2  1  2G sin2 ø  G
 

2  0.84  3

 32  1  2  3  (0.3123)2  3
 
 45.11
 T  45 teeth
 t  15 teeth
L.P.C  R A
2
2
2
 (1)
 m  t m  15 
 r  2  2  7.5m 
 
  7.5m  0.84m 
 
  8.34m 
 mT m  45 
R    22.5m 
 2 2 
 RA  R  addendum 
 
  22.5m  0.84m 
  23.34m 
 
putting all values in equation (1)
  (23.34m)  22.5m 0.95  22.5m 0.3122   (8.34m)  7.5m  0.95  7.5m 0.3122
2 2 2 2
 4.343m
4.343m 3.876m
L.A.C  
cos ø 0.95
L.A.C  4.57m
III. Pinion gear with a rack
Min. no. of teeth on pinion t
2 AR 2  0.84
t 
sin  (0.3123)2
2
 t  17.23
 t  18

L.P.C R A
2
2
 rA 2  rcos ø   rsin ø
2

 2 r  rcos ø   rsin ø 
2 2
A ( assume rack andpinion same dimension)
 mt 18m 
 r  2  2  9m 
2  (9.84)  9m 0.95  9m 0.3123
2 2 
  9m  0.84m 

 
  9.84m 
 4.12m
4.12m 4.12m
L.A.C  
cos ø 0.95
L.A.C  4.337m
Ex. 7.18 The gearing of a machine tool is shown in the figure. The motor shaft is connected to
gear A and rotates at 975 RPM. The gear wheels B, C, D, and E are fixed to parallel shafts
rotating together. The final gear F is fixed on the output shaft. What is the speed of gear
F? The number of teeth on each gear is as given below:
Gear A B C D E F
No. of teeth 20 50 25 75 26 65
TA  20 NF  ?
TB  50
TC  25
TD  75
TE  26
TF  65
NA  975 rpm
NF TA TC TE
  
NA TB TD TF
NF 20 20 26
   
975 50 75 65
NF  52 rpm
Ex. 7.19 In an epicyclic gear train, an arm carries two gears A and B having 36 and 45 teeth
respectively. If the arm rotates at 150 rpm in the anticlockwise direction about the center
of the gear A which is fixed, determine the speed of gear B. If the gear A instead of being
fixed makes 300 rpm in the clockwise direction, what will be the speed of gear B?
TA  36 Gear A fixed  NB  ?
TB  45 NA  300(Clockwise)  NB  ?
NC  150(Anticlockwise)
Sr. Revolution of element

Condition of motion
No. Arm C Gear A Gear B
Arm fixe, gear A rotates +1 TA

1 0 +1 
revolution(anticlockwise) TB
Arm fixed gear A rotates TA

2 0 x x
through + x revolutions TB
Add + y revolutions to all

3 y y y
elements
TA
4 Total motion y x y y- x
TB
1. Speed of gear B (NB) when gear A is fixed
Here, gear A fixed

xy0
 x  150  0
 x  150

TA
Speed of gear B (NB)  y  x
TB
36
 y  (150)
45
 270rpm (Anticlockwise)
2. Speed of gear B (NB) when gear NA = -300 (Clockwise)
Here given
x  y  300
 x  150  300
 x  450 rpm
Speed of gear B (NB)
TA
 yx
TB
36
 150  (450)
45
 510 rpm(Anti clockwise)
Ex. 7.20 In a reverted epicyclic gear train, the arm A carries two gears B and C and a compound
gear D - E. The gear B meshes with gear E and the gear C meshes with gear D. The number
of teeth on gears B, C and D are 75, 30 and 90 respectively. Find the speed and direction
of gear C when gear B is fixed and the arm A makes 100 rpm clockwise.
TB  75 GearBfixed  NC  ?
TC  30 NA  100  NC  ?
TD  90
NA  100(Clockwise)

Let dC  dD  dB  dE (rC  rD  rB  rE )
 TC  TD  TB  TE
30  90  75  TE
 TE  45

Condition of motion
No. Arm C Gear A Gear B Gear C
Arm fixe, gear A rotates +1 TE TD

1 0 +1  
revolution(anticlockwise) TB TC
Arm fixed gear A rotates x

TE
x
TD
2 0 x
through + x revolutions TB TC

3 y y y y
elements
TE TD
4 Total motion y x y yx yx
TB TC
TE
GearBis fixed  y  x 0
TB
45
 100  x  0
75
 x  166.67
TD
Speed of gear C (NC )  y  x
TC
90
 100  (166.67) 
30
 400 rpm(Anti clockwise)

Condition of motion
Arm fixe, gear A rotates
TB TB TD
1 +1 0 +1   
TE TE TC
revolution(anticlockwise)
Arm fixed gear A rotates TB

x
TB TD

2 0 x x
through + x revolutions TE TE TC

3 y y y y
elements
TB TB TD
4 Total motion y x y yx yx 
TE TE TC

From fig (rC  rD  rB  rE )
 TC  TD  TB  TE
 TE  90  30  75
 TE  45
When gear B is fixed

x  y  0
 x  (100)  0
 x  100
TB TD
Now NC  y  x 
TE TC
75 90
 100  100  
45 30
NC  400 rpm (Anticlockwise)
Ex. 7.21 An epicyclic gear consists of three gears A, B and C as shown in the figure. The gear A
has 72 internal teeth and gear C has 32 external teeth. The gear B meshes with both A
and C and is carried on an arm EF which rotates about the center of A at 18 RPM. If the
gear A is fixed, determine the speed of gears B and C.
TB  72 (Internal) Gear A fixed  NB  ?

TC  32 (External)  NC  ?
ArmEF  18rpm
From the geometry of the figure,
rA  rC  2rB
 TA  TC  2TB
 TB  20

Condition of motion
TC TC TB T
1 +1 revolution 0 +1     C
TB TB TA TA
(anticlockwise)
Arm fixed gear A rotates TC TC

2 0 +x x x
through + x revolutions TB TA

3 +y +y +y +y
elements
TC TC
4 Total motion y x+y yx yx
TB TA
1. Speed of gear C (Nc)
TC
Gear Ais fixed  y  x 0
TA
32
 18  x  0
72
 x  40.5
Speed of gear C (NC )  x  y

 40.5  18
 58.5rpm(inthedirectionof arm)
2. Speed of gear B (NB)
TC
Speedof gearB  y  x
TB
32
 18  40.5 
20
 46.8 rpm
 46.8 rpm (intheopposite direction of arm)
Ex. 7.22 Two shafts A and B are co-axial. A gear C (50 teeth) is rigidly mounted on shaft A. A
compound gear D-E gears with C and an internal gear G. D has 20 teeth and gears with C
and E has 35 teeth and gears with an internal gear G. The gear G is fixed and is concentric
with the shaft axis. The compound gear D-E is mounted on a pin which projects from an
arm keyed to the shaft B. Sketch the arrangement and find the number of teeth on internal
gear G assuming that all gears have the same module. If the shaft A rotates at 110 rpm,
find the speed of shaft B.

TC  50 No.of teethon internal gear  ?

TD  20 Speed of shaft B  ?
TE  35
NC  110 (Rotationof shaft)
Revolution of element
Sr.
Condition of motion Gear C Compound
No. Arm C Gear G
(Shaft A) Gear (D-E)

TC TC TE
1 +1 0 +1   
TD TD TG
Arm fixed gear A rotates x

TC
x
TC TE

2 0 +x
through + x revolutions TD TD TG

3 +y +y +y +y
elements
TC TC TE
4 Total motion y x+y yx yx 
TD TD TG
dG dC dD dE
  
2 2 2 2
dG  dC  dD  dE
 TG  TC  TD  TE
 TG  50  20  35
 TG  105
Speed of shaft B
Here given gear G is fixed
TC TE
y  x  0
TD TG
50 35
y  x  0
20 105
5
y  x   0 (1)
6
Also given gear C is rigidly mounted on shaft A
x  y  110 (2)
Solving Eq. (1) & (2)
x  60
y  50
Speed of shaft B  Speed of arm   y  50 rpm
Ex. 7.23 In an epicyclic gear train, as shown in the figure, the number of teeth on wheels A, B and
C are 48, 24 and 50 respectively. If the arm rotates at 400 rpm, clockwise,
Find:
1. Speed of wheel C when A is fixed, and
2. Speed of wheel A when C is fixed

TA  48 Gear A fixed  NC  ?
TB  24 GearCfixed  NA  ?
TC  50 y  400 rpm (Arm rotationclockwise)

Condition of motion
TA  TA   TB  TA
1 +1 0 +1        
TB  TB   TC  TC
Arm fixed gear A rotates TA TA

2 0 x x x
through + x revolutions TB TC

3 y y y y
elements
TA TA
4 Total motion y x y yx yx
TB TC
1. Speed of wheel C when A is fixed
When A is fixed
xy0
 x  400  0
x0
TA
NC  y  x
TC
48
 400  400 
50
 16 rpm
NC  16 rpm (Clockwise direction)
2. Speed wheel A when C is fixed
When C is fixed
NC  0
T
y  x A  0
TC
48
400  x  0
50
 x  416.67
NA  x  y
 416.67  400
NA  16.67 (Anticlockwise)
Ex. 7.24 An epicyclic gear train, as shown in the figure, has a sun wheel S of 30 teeth and two
planet wheels P-P of 50 teeth. The planet wheels mesh with the internal teeth of a fixed
annulus A. The driving shaft carrying the sun wheel transmits 4 kW at 300 RPM. The
driven shaft is connected to an arm which carries the planet wheels. Determine the speed
of the driven shaft and the torque transmitted, if the overall efficiency is 95%.

TS  30 TP  50 TA  130
NS  300 rpm P  4 KW
rA  2rP  rS
 TA  2TP  TS
 2  50  30
 130
Sr.
Condition of motion
No.
Arm C Gear A Gear B Gear C

TS  TS   TP  TS
1 +1 0 +1       
TP  TP   TA  TA
Arm fixed gear A rotates TS TS

2 0 x x x
through + x revolutions TP TA

3 y y y y
elements
TS TS
4 Total motion y x y yx yx
TP TA
Here,
NS  300rpm
 x  y  300 (1)

Also, Annular gear A is fixed
TS
y  x 0
TA
30
y  x  0
130
 y  0.23x (2)
Solving equation eq. (1) & (2)
x  243.75
y  56.25
Speed of Arm = Speed of driven shaft = y = 56.25 rpm
Here, P = 4 KW &   95%
Pout
 
Pin
Pout   Pin
95
 4
100
 3.8 KW
Also,
2NT
Pout 
60
2 56.30T
3.8 103 
60
 T  644.5 N  m
Ex. 7.25 An epicyclic gear train is shown In figure. Find out the rpm of pinion D if arm A rotates at
60 rpm in the anticlockwise direction.

TD  40 ND  ?
TC  60
TB  120
NA  60 rpm (Anticlockwise)

Condition of motion
No. Arm C Gear B Gear C Gear D
TB TB TC T
1 +1 0 +1    B
TC TC TD TD
Arm fixed gear A rotates TB TB

2 0 x x x
through + x revolutions TC TD

3 y y y y
elements
TB TB
4 Total motion y x y yx yx
TC TD
From fig. Gear B is fixed

x  y  0
 x  60  0 ( rpmof armA  60  y)
 x   60
Now the motion of gear D
TB
yx
TD
120
 60  60 
40
 120 rpm
D rotates 120 rpm in the clockwise direction.
Ex. 7.26 An epicyclic gear train for an electric motor is shown in the figure. The wheel S has 15
teeth and is fixed to the motor shaft rotating at 1450 RPM. The planet P has 45 teeth,
gears with fixed annulus A and rotates on a spindle carried by an arm that is fixed to the
output shaft. The planet P also gears with the sun wheel S. Find the speed of the output
shaft. If the motor is transmitting 1.5 kW, find the torque required to fix the annulus A.

TS  15 Speedof outputshaft  ?
TP  45 Torque  ?
From figure,
rA  rs  2rP
 TA  TS  2TP
 TA  105

Condition of motion
No. Spindle Gear S Gear P Gear A
Sector/Spindle fixed,
gear S rotates +1 TS TS TP T
1 0 +1     S
revolution TP TP TA TA
(anticlockwise)
Spindle fixed gear S
TS TS
2 rotates through + x 0 x x x
TP TA
revolutions
Add + y revolutions to
3 y y y y
all elements
TS TS
4 Total motion y x y yx yx
TP TA
Motor shaft is fixed with gear S
 x  y  1450 (1)
And Annular A is fixed
TS
y  x 0
TA
15
y  x 0
105
15
y  x (2)
105
By solving equation (1) & (2)
x  1268.76
y  181.25
Speed of output shaft y = 181.25 rpm
 Torque on sun wheel (S) (input torque)
2NTi
P
60
P  60
 Ti 
2N
 2  103  60  2 
   1.35HP  1KW  2 HP  KW 
 1.35  2 1450  1.35 
 9.75N  m

 Torque on output shaft (with 100% mechanical efficiency)
P  60
 To 
2N
 2  103  60
 
 1.35  2 181.25
 78.05 N  m
 Fixing torque
 To  Ti
 78.05  9.75
 68.3N  m
Ex. 7.27 If wheel D of gear train as shown in the figure, is fixed and the arm A makes 140
revolutions in a clockwise direction. Find the speed and direction of rotation of B & E. C
is a compound wheel.
TB  30 TC  35 TD  19 TE  30

Condition of motion
No. Spindle Gear S Gear P Gear A
20  20   35   19 
1 +1 0 +1        
15  15   19   30 
Arm fixed gear A rotates

2 0 x 1.33x 1.555x
through + x revolutions
3 y y y y
elements
4 Total motion y x y y  1.33x y 1.555x

 When gear D is fixed
y  2.456x  0
140  2.456x  0 ( y  140rpm given)
x  57
 Speed of gear B
NB  x  y
 57  140
 83rpm(Clockwise)
 Speed of gear E
NE  y  1.555x
 140  1.555(57)
 228.63rpm (Clockwise)
Ex. 7.28 The epicyclic train as shown in the figure is composed of a fixed annular wheel A having
150 teeth. Meshing with A is a wheel b which drives wheel D through an idle wheel C, D
being concentric with A. Wheel B and C is carried on an arm which revolves clockwise at
100 rpm about the axis of A or D. If the wheels B and D are having 25 teeth and 40 teeth
respectively, Find the no. of teeth on C and speed and sense of rotation of C.
Solution:
From the geometry of figure,
rA  2rB  2rC  rD
 TA  2TB  2TC  TD
150  50  2TC  40
 TC  30

Condition of motion
No. Arm Gear D Gear C Gear B Gear A
Arm fixe, gear D

TD TD
1 rotates +1 revolution 0 +1   TD
TC TB 
(anticlockwise) TA
Arm fixed gear D

TD TD TD
2 rotates through + x 0 x x x x
TC TB TA
revolutions
Add + y revolutions
3 y y y y y
to all elements
TD TD TD
4 Total motion y x y yx yx yx
TC TB TA

Now
NA  0
TD
y  x 0
TA
40
100  x  0
150
 x  375
Let
TD
NC  y  x
TC
40
 100  375 
30
 600rpm
Ex. 7.29 The figure shows a differential gear used in a motor car. The pinion A on the propeller
shaft has 12 teeth and gears with the crown gear B which has 60 teeth. The shafts P and
Q from the rear axles to which the road wheels are attached. If the propeller shaft rotates
at 1000 rpm and the road wheel attached to axle Q has a speed of 210 rpm. while taking
a turn, find the speed of the road wheel attached to axle P.

TA  12
TB  60
NQ  ND  210rpm
NA  1000rpm
Let,
NA  TA  NB TB
T
NB  NA  A
TB
12
 1000 
60
 200rpm

Condition of motion
No. Gear B Gear C Gear E Gear D
Gear B is fixed, gear C
TC
1 rotates +1 0 +1  -1
TE
Gear B is fixed gear C
TC
2 rotates through + x 0 x x x
TE
revolutions
3 y y y y
elements
TC
4 Total motion y x y yx yx
TE
Let here speed of gear B is 200 rpm

NB  200  y
From table
ND  y  x  210
 x  y  210
 x  200  210
 x  10rpm
Let the speed of road wheel attached to the axle P = Speed of gear C
xy
 10  200
 180rpm
Ex. 7.30 Two bevel gears A and B (having 40 teeth and 30 teeth) are rigidly mounted on two co-
axial shafts X and Y. A bevel gear C (having 50 teeth) meshes with A and B and rotates
freely on one end of an arm. At the other end of the arm is welded a sleeve and the sleeve
is riding freely loose on the axes of the shafts X and Y. Sketch the arrangement. If the
shaft X rotates at 100 RPM. clockwise and arm rotates at 100 RPM. anticlockwise, find
the speed of shaft Y.

TA  40 TC  50 TB  30
NX  NA  100rpm(Clockwise)
Speedof arm  100rpm

Condition of motion
No. Arm Gear A Gear C Gear B
Arm fixe, gear A rotates +1 TA TA

1 0 +1  
revolution(anticlockwise) TC TB
Arm fixed gear A rotates TA TA

2 0 x x x
through + x revolutions TC TB

3 y y y y
elements
TA TA
4 Total motion y x y yx yx
TC TB
Here speed of arm = y =+100 rpm (given)
Also given NA  NX  100rpm

NA  x  y
100  x  100
x  200
Speed of shaft Y  NB
TA
 yx
TB
40
 100  200 
30
 366.7rpm (Anticlockwise)
Ex. 7.31 An epicyclic train of gears is arranged as shown in the figure. How many revolutions does
the arm, to which the pinions B and C are attached, make: 1. when A makes one revolution
clockwise and D makes half a revolution anticlockwise, and 2. when A makes one
revolution clockwise and D is stationary? The number of teeth on the gears A and D are
40 and 90 respectively.

TA  40
TD  90
First of all, let us find the number of teeth on gear B and C (i.e. T B and Tc). Let dA, dB, dC, dD be the pitch
circle diameter of gears A, B, C, and D respectively. Therefore from the geometry of fig,
dA + dB + dC = dD or dA + 2 dB = dD ...( dB = dC )
Since the number of teeth is proportional to their pitch circle diameters, therefore,
TA + 2 TB = TD or 40 + 2 TB = 90
 TB = 25, and TC = 25 ...( TB = TC )
Revolutions of elements
Sr.
Conditions of motion Compound
No. Arm Gear A Gear D
Gear B-C
Arm fixe, gear A rotates TA  TA   TB  TA

1 0 1        
-1 revolution(clockwise) TB  TB   TD  TD
Arm fixed gear A rotates x

TA
x
TA
2 0 x
through - x revolutions TB TD
Add - y revolutions to all y y y y

3
elements
TA TA
4 Total motion y x  y x y x y
TB TC
1. Speed of arm when A makes 1 revolution clockwise and D makes half revolution
anticlockwise
Since the gear A makes 1 revolution clockwise, therefore from the fourth row of the table,
x  y  1 or x  y 1 ...(1)
Also, the gear D makes half revolution anticlockwise, therefore
TA 1
x y
TD 2
40 1
x   y 
90 2
 40x  90y  45
 x  2.25y  1.125 ...(2)
From equations (1) and (2),

x  1.04 and y  0.04
Speed of arm  y  (0.04)  0.04
 0.04 revolution(Anticlockwise)
2. Speed of arm when A makes 1 revolution clockwise and D is stationary

Since the gear A makes 1 revolution clockwise, therefore from the fourth row of the table,
x  y  1
x  y  1 ...(3)
Also, the gear D is stationary, therefore
TA
x y0
TD
40
x   y  0
90
 40x  90y  0
 x  2.25y  0 ...(4)

Speedof arm  y  0.308
Speedof arm  0.308revolution (Clockwise)
Ex. 7.32 In an epicyclic gear train, the internal wheels A and B and compound wheels C and D
rotate independently about axis O. The wheels E and F rotate on pins fixed to the arm G.
E gears with A and C and F gears with B and D. All the wheels have the same module and
the number of teeth are: TC = 28; TD = 26; TE = TF = 18. 1. Sketch the arrangement; 2.
Find the number of teeth on A and B; 3. If the arm G makes 100 r.p.m. clockwise and A is
fixed, find the speed of B; and 4. If the arm G makes 100 r.p.m. clockwise and wheel A
makes 10 r.p.m. counter-clockwise; find the speed of Wheel B.
TC = 28 ; TD = 26 ; TE = TF = 18
1. Sketch the arrangement
The arrangement is shown in the figure.
2. Number of teeth on wheels A and B

TA = Number of teeth on wheel A, and
TB = Number of teeth on wheel B.
If dA, dB, dC, dD, dE and dF are the pitch circle diameters of wheels A, B, C, D, E, and F respectively,
then from the geometry of Fig.
dA = dC + 2 dE
And dB = dD + 2 dF

Since the number of teeth is proportional to their pitch circle diameters, for the same module,
therefore
TA = TC + 2 TE = 28 + 2 = 64
And TB = TD + 2 TF = 26 + 2 = 62
3. Speed of wheel B when arm G makes 100 r.p.m. clockwise and wheel A is fixed
First of all, the table of motions is drawn as given below:
Sr. Conditions of
Arm Wheel Wheel Compound
No motion Wheel F Wheel B
G A E wheel C-D
Arm fixe, A TA TE TA TD TF
rotates     
TA TE TC TA TD TC TF TB
1 0 1   
+1 revolution TE TA TC TF TA TD
  
(Anti clockwise) TC TC TB
Arm fixed A
TA TA TA TD TA TD
2 rotates through + 0 x x x x  x 
TE TC TC TF TC TB
x revolutions
Add +y
3 revolutions to all y y y y y y
elements
4 Total motion y x y TA TA TA TD TA TD
x y yx y  x  y  x 
TE TC TC TF TC TB
Since the arm G makes 100 r.p.m. clockwise, therefore from the fourth row of the table
y =  100
Also, wheel A is fixed, therefore from the fourth row of the table,
x+y=0 or x = -y=100
TA TD
Speedof wheel B  y  x  
TC TB
64 26
 -100  100  
28 62
 -100  95.8 r.p.m.  - 4.2r.p.m
Speedof wheel B  4.2 r.p.m (Clockwise)
4. Speed of wheel B when arm G makes 100 r.p.m. clockwise and wheel A makes 10 r.p.m. counter-
clockwise
Since the arm G makes 100 r.p.m. clockwise, therefore from the fourth row of the table
y  100 ...(3)
Also, wheel A makes 10 r.p.m. counter-clockwise, therefore from the fourth row of the table,

x  y  10
 x  10  y
 x  10  100
 x  110 ...(4)
TA TD
 Speed of wheel B   y  x  
TC TB
64 26
 100  110  
28 62
 100  105.4 r.p.m
 5.4 r.p.m
 Speed of wheel B  5.4r.p.m (Anticlockwise)
Ex. 7.33 The figure shows diagrammatically a compound epicyclic gear train. Wheels A, D and E
are free to rotate independently on spindle O, while B and C are compound and rotate
together on spindle P, on the end of arm OP. All the teeth on different wheels have the
same module. A has 12 teeth, B has 30 teeth and C has 14 teeth cut externally. Find the
number of teeth on wheels D and E which are cut internally. If the wheel A is driven
clockwise at 1 r.p.s. while D is driven counter-clockwise at 5 r.p.s., determine the
magnitude and direction of the angular velocities of arm OP and wheel E.
Solution: Given: TA  12; TB  30; TC  14; NA  1 r.p.s.; ND  5r.p.s

Number of teeth on wheels D and E
Let TD and TE as the number of teeth on wheels D and E respectively. Let dA, dB, dC, dD, and dE be the pitch
circle diameters of wheels A, B, C, D, and E respectively. From the geometry of the figure,
dE  dA  2dB and dD = dE  (dB  dC )
Since the number of teeth is proportional to their pitch circle diameters for the same module, therefore
TE  TA  2TB TD  TE  (TB  TC )
 TE  12  2  30  TD  72  (30  14)
 TE  72  TD  56

Magnitude and direction of angular velocities of arm OP and wheel
The table of motions is drawn as follows:
Sr.
Condition of motion Wheel Compound
No. Arm Wheel D Wheel E
A wheel B-C
Arm fixe, gear A rotates TA TA TC TA TB T

1 0 -1       A
-1 revolution(clockwise) TB TB TD TB TE TE
Arm fixed gear A rotates TA TA TC TA

2 0 x x x  x
through - x revolutions TB TB TD TE
Add - y revolutions to all y y y y y

3
elements
TA TA TC TA
4 Total motion y x  y x y x  y x y
TB TB TD TE
Since the wheel A makes 1 r.p.s. clockwise, therefore from the fourth row of the table,
 x  y  1
x  y  1 (1)
Also, the wheel D makes 5 r.p.s. counter-clockwise, therefore
TA TC
x  y5
TB TD
T T
x A  C  y  5
TB TD
12 14
x   y  5
30 56
 0.1x  y  5 (2)
x  5.45 and y  -4.45
Angular velocity of arm OP
 y  (4.45)  4.45 r.p.s
 4.45  2  27.964rad / sec (Anti clockwise)
And the angular velocity of wheel E

TA
x y
TE
12
 5.45   (4.45)
72
 5.36 r.p.s
 5.36  2
 33.68 rad / sec (Anti clockwise)

Ex. 7.34 The figure shows an epicyclic gear train known as Ferguson’s paradox. Gear A is fixed to
the frame and is, therefore, stationary. The arm B and gears C and D are free to rotate on
the shaft S. Gears A, C and D have 100, 101 and 99 teeth respectively. The planet gear
has 20 teeth. The pitch circle diameters of all are the same so that the planet gear P
meshes with all of them. Determine the revolutions of gears C and D for one revolution of
the arm B.
Solution: Given : TA = 100 ; TC = 101 ; TD = 99 ;TP = 20

The table of motions is given below:
Sr.
Condition of motion Arm Gear
No. Gear C Gear D
B A
Arm B fixe, gear A rotates +1 TA TA TC TA
1 0 +1    
revolution(anticlockwise) TC TC TD TD
Arm B fixed gear A rotates through + x TA TA
2 0 x x x
revolutions TC TD
3 Add + y revolutions to all elements y y y y
TA TA
4 Total motion y x y yx yx
TC TD
The arm B makes one revolution, therefore

y=1
Since the gear A is fixed, therefore from the fourth row of the table,
x+y=0
x  y  1
Let NC and ND = Revolutions of gears C and D respectively.

From the fourth row of the table, the revolutions of gear C,
TA
NC  y  x
TC
100
1  1 
101
1
NC  
101
And the revolutions of gear D,
TA 100
ND  y  x  1
TD 99
1
 ND  
99
From above we see that for one revolution of the arm B, the gear C rotates through 1/101 Revolution in
the same direction and the gear D rotates through 1/99 revolutions in the opposite direction.
Ex. 7.35 The figure shows an epicyclic gear train. Pinion A has 15 teeth and is rigidly fixed to the
motor shaft. The wheel B has 20 teeth and gears with A and also with the annular fixed
wheel E. Pinion C has 15 teeth and is integral with B (B, C being a compound gear wheel).
Gear C meshes with annular wheel D, which is keyed to the machine shaft. The arm
rotates about the same shaft on which A is fixed and carries the compound wheel B, C. If
the motor runs at 1000 r.p.m., find the speed of the machine shaft. Find the torque
exerted on the machine shaft, if the motor develops a torque of 100 N-m.
Solution: Given : TA = 15 ; TB = 20 ; TC = 15 ; NA = 1000 r.p.m.;

Torque developed by motor (or pinion A) = 100 N-m
1. Speed of the machine shaft
The table of motions is given below:
Sr.
Condition of motion Pinion Compound
No. Arm Wheel D Wheel E
A wheel D-C
TA TA TC TA TB T
1 +1 0 +1       A
TB TB TD TB TE TE
Arm fixed gear A rotates TA TA TC TA

2 0 x x x  x
through + x revolutions TB TB TD TE

3 y y y y y
elements
TA TA TC TA
4 Total motion y x y yx yx  yx
TB TB TD TE

First of all, let us find the number of teeth on wheels D and E. Let T D and TE as the number of teeth on
wheels D and E respectively. Let dA, dB, dC, dD, and dE be the pitch circle diameters of wheels A, B, C, D,
and E respectively. From the geometry of the figure,
dE = dA + 2 dB and dD = dE -(dB -dC )
Since the number of teeth is proportional to their pitch circle diameters, therefore,
TE = TA + 2 TB = 15 + 2  20 = 55
TD = TE  (TB  TC )  55  (20  15)  50
We know that the speed of the motor or the speed of the pinion A is 1000 r.p.m.
Therefore
x + y = 1000 ...(1)
Also, the annular wheel E is fixed, therefore
TA
yx 0
TE
TA
y  x
TE
15
y  x
55
 y  0.273x ...(2)
x = 786 and y = 214
 Speedofmachineshaft  Speedof wheel D
T T
ND  y  x A  C
TB TD
15 15
 214  786  
20 50
  37.15 r.p.m.
ND  37.15 (Anticlockwise)
The torque exerted on the machine shaft

We know that
Torque developed by motor  Angular speed of motor
 Torque exerted on machine shaft  Angular speed of machine shaft
100  A  Torque exerted on machine shaft  D

 Torque exerted on machine shaft  100  A
D
N 1000
 100  A  100 
ND 37.5
 Torque exerted on machine shaft  2692 N  m

Ex. 7.36 An epicyclic gear train consists of a sun wheel S, a stationary internal gear E and three
identical planet wheels P carried on a star-shaped planet carrier C. The sizes of different
toothed wheels are such that the planet carrier C rotates at 1/5th of the speed of the sun
wheel S. The minimum number of teeth on any wheel is 16. The driving torque on the sun
wheel is 100 N-m. Determine 1. Number of teeth on different wheels of the train, and 2.
torque necessary to keep the internal gear stationary.
Solution: NS
Given NC 
5
1. Number of teeth on different wheels
The arrangement of the epicyclic gear train is shown in the figure. Let TS and TE as the number of teeth
on the sun wheel S and the internal gear E respectively. The table of motions is given below:
Sr.
Conditions of motion Plant carrier Sun wheel Planet
No. Internal Gear E
C S Wheel P
Planet carrier C fixed,
sun wheel S rotates 
TS

TS TP T
  S
1 0 +1
through + 1 revolution TP TP TE TE
(anticlockwise)
Planet carrier C fixed,
TS TS
2 sun wheel S rotates 0 x x x
TP TE
through + x revolutions
Add + y revolutions to
3 y y y y
all elements
TS TS
4 Total motion y x y yx yx
TP TE
We know that when the sun wheel S makes 5 revolutions, the planet carrier C makes 1 revolution.
Therefore from the fourth row of the table,
y  1, and x  y  5
x  4

Since the gear E is stationary, therefore from the fourth row of the table,
TS
yx 0
TE
TS
1  4 0
TE
 TE  4TS
Since the minimum number of teeth on any wheel is 16, therefore let us take the number of teeth on the
sun wheel,
TS  16
 TE  4  16  64
Let dS, dP, and dE be the pitch circle diameters of wheels S, P and E respectively. Now from the geometry
of Fig
dS + 2 dP = dE
Assuming the module of all the gears to be the same, the number of teeth is proportional to their pitch
circle diameters.
TS  2 TP  TE
16  2TP  64
 TP  24
2. Torque necessary to keep the internal gear stationary

We know that
Torque on S  Angular speed of S  Torque on C  Angular speed of C
100  S  Torque on C  C

 Torque on C  100  S
C
N
 100  S
NC
 100  5
 Torque on C  500 N  m
 Torque necessary to keep the internal gear stationary
 500  100
 400 N  m
References:
3. Theory of machines and mechanisms, Ballaney P. L., Khanna Publishers


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Contents

1.1 Concepts of Kinematics and Dynamics .......................................................................................... 1.2

Table 1.1 - Difference Between a Machine and a Structure

1.2 Kinematic Links

1.2.1 Types of Kinematic Links

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

Fig.1.2 - Chain Drive

Fig.1.3 - Hydraulic jack

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

Fig.1.4 - The motion of a square bar in a square hole

b) Incompletely Constrained Motion

Fig.1.6 - A circular bar or shaft in a circular hole

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

Fig.1.7 - Shaft in a foot-step bearing

1.4 Kinematic Pair

1.4.1 According to the type of relative motion between the elements

Fig.1.8 - Piston and Cylinder

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

Fig.1.9 Circular shaft revolving inside a bearing

Fig.1.10 - Ball bearing

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

Fig.1.11 - Bolt with a nut

Fig.1.12 - Ball and socket joint

1.4.2 According to the type of contact between the elements

Fig.1.13 - Types of lower pair

Fig.1.14 - Cam and Follower

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

Fig.1.15 - Bolt with a nut

b) Force - closed pair

Fig.1.16 - Cam and follower with spring

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

Table 1.2 - Difference Between Kinematic Pair and Kinematic Chain

Kinematic Pair Kinematic Chain

 A mechanism with more than four links is known as a compound mechanism.

1.6 Degrees of freedom/mobility of a mechanism

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

Fig.1.17 - Plane mechanisms

1.6.2 Grubler’s Criterion for Plane Mechanisms

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

1.7.1 Types of Kinematic Chains

1.8 Four Bar Chain or Quadric Cycle Chain

Fig.1.18 - Four Bar Chain

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

1.8.1.1 Beam engine (crank and lever mechanism)

Fig.1.19 - Beam engine

1.8.1.2 Coupling rod of a locomotive (Double crank mechanism)

Fig.1.20 - Coupling rod of a locomotive

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

Fig.1.21 - Watt's straight-line mechanism

1.9 Single Slider Crank Chain

Fig.1.22 - Single slider crank chain

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

1.9.1.1 Pendulum pump or Bull engine

Fig.1.23 - Pendulum pump

1.9.1.2 Oscillating cylinder engine

Fig.1.24 - Oscillating cylinder engine

Prof. Sunil G. Janiyani, Department of Mechanical Engineering

Fig.1.25 - Rotary internal combustion engine

1.9.1.4 Crank and slotted lever quick return motion mechanism

Fig.1.26 - Crank and slotted lever quick return motion mechanism