1. Thermodynamics Different systems (Open, Close, etc.) and processes (isothermal, adiabatic, etc.

) Laws of thermodynamics, P-V work in various processes, Application of 1st law in different processes, Entropy and Enthalpy, Ideal gas equations and Cp & Cv, Heat engine 2. Energy conversion devices Package Boiler, reciprocating compressor, rotary compressors 3. Power Plants Thermal, Hydroelectric 4. Introduction to manufacturing processes and Their Applications: Casting, Sheet metal forming, Sheet metal cutting, Forging, fabrication, Metal joining processes.

EME, to be covered
y Power Transmission Devices
y Types of Belts and belt drives, Chain drive, Types of gears, Types of

Couplings, friction clutch (cone and single plate), brakes (types and applications only) Applications of these devices

y Machine elements: y Power transmission shafts, axles, keys, bush and ball bearings, Flywheel and Governors
y Mechanisms:.(Descriptive treatment only)
y Slider crank mechanism, Four bar chain mechanism, List of various

inversions of Four bar chain mechanism, Geneva mechanism, Ratchet and Paul mechanism

Power Transmission Devices

y Objective: Transfer power from y Prime mover to machine y Long distance power transfer y One shaft to another shaft y Modify the speed/force y Control the power y Methods to transmit power y Belts y Ropes y Chains y Gears

Belt Drives
y Advantages y Simple and economic y No need of parallel shafts, tolerates misalignments y Vibrations, load fluctuation damping y Overload, jam protection y High efficiency (95%) y Disadvantages y Non positive drive y Angular velocity ratio is not constant. Slip is present y Heating limits maximum speed. y Power transmission limited to 350 kw. y Installation arrangements needed for endless belts

Types and material of belts

y Types of belt
y Flat belt: Rubberized fabric, sometimes Steel y V Belts: Textile fabrics covered with rubber y Circular Belts OR Ropes: leather y Timing Belts: Rubber

Types of Belt Drives

y Open Belt drive y Driver and follower move in same direction

y dL - Diameter of the larger pulley y dS Diameter of the smaller pulley y L- Angle of wrap of the larger pulley y S Angle of wrap of the smaller pulley y C- Center distance between the two pulleys L

Wrap angle and belt length of open belt drive

y Cross Belt drive y Driver and follower move in opposite directions y Provides more angle of contact, hence lesser slip

Wrap angle and belt length of cross belt drive

Law of Belting
y The centre line of belt approaching

a pulley must lie in the mid plane of that pulley.

y However, the belt leaving pulley

may be drawn out of the plane.

Types of Pulley
y Idler Pulley y Intermediate Pulley y Loose and Fast Pulley y Guide Pulley (To satisfy law of belting) y Crowning of Pulley
y Edge E has more tension than F. It pushes

the belt to centre

Velocity ratio of belt drives

y VR = N2 / N1 = d1 / d2 = w2 / w1
N2 : speed of follower in rpm N1 : speed of driver in rpm w = 2 N/60 rad/s

y Considering belt thickness and Slip

Belt tension ratio

Ratio of Belt tensions

Effect of centrifugal forces on power transmission

y Centrifugal tension Tc = mV y Velocity Ratio y Power transmission P = (T1

T2)v

y Condition for maximum power transmission for given T

y y y

T = 3 Tc T1 = T Tc = 2/3 T Vmax = T/3m

y Belt Design: For given belt property m, ,

and allowable T, find power transmission. OR for necessary power transmission, find belt parametres (Tutorial)

Creep
y Tension on belt changes from T1 to T2. This causes sliding of belt on pulley. This is called creeps y Creep reduces the VR, and hence reduces power transmission

Compound Belt Drive

y Provide higher velocity ratio

y N4/N1 = d1/d2 * d3/d4

= product of diameters of driver pulleys/ product of diameters of driven pulleys

V Belt
y For large power transmission y For short centre distances y No slipping of belt y Can be used in groups

y 2B = angle of groove

Example
y A flat belt 8 mm thick and 100 mm wide y It is running at 1600 m/min y The mass of belt 0.9 kg/m y Angle of lap in smaller pulley is 165 y Coefficient of friction 0.3 y Max permissible stress in belt 2 MN/m y Find y Max power transmitted

Solution
y Tmax = stress * area

= 2 * 10 * 0.008 * 0.1 = 1600 N Tc = mv = 0.9 * 26.67 = 640 N T1 = Tmax Tc = 960 N = e(0.3 * 165 *3.14/180) = 2.373

y T2 = 960 / 2.373 = 404.7 N y P = (T1

T2)*v = (960 404.7)*26.67 = 14807.6 w = 14.807 kw

Chain Drives
y Positive drive y Used in Chain-sprocket pair y Noisy on high speed y Suitable for low to medium power y Needs lesser adjustment, has no slipping off y Permits good variation in centre distance y Types y Roller chain y Silent chain

Roller Chain
y Has rollers to reduce friction with sprocket y All contact surfaces are hardened to reduce wear

Silent OR inverted tooth chain

y Has no space to free movement hence its operation is

silent y Teeth meets the contact faces on sprockets y Teeth angle 60 to 75 degree

Polygonal Effect
y Chain drive has constant velocity ratio over the

rotations y In rotation the VR has variations due to polygonal effect

Gear drive
y y y y

Close distance Positive drive No slip High torque

y Types of Gears y Spur gears y Helical gears y Bevel gears y Worm gears y Rack and pinion y Spiral gears

Spur Gears
y Parallel shafts y Teeth are parallel to shaft y Where have you seen it?

Helical Gears
y Helical Gears y Parallel shafts y Teeth have helical path y Mating gears have equal helix angle and opposite hand y No tooth impact. Gradual contact of tooth y Smooth, Silent, used at high speed y Generates axial thrust y Double helical gears y No axial thrust y Difficult to manufacture y Herringbone gears y Double helical gear with grove

Helical Gears
Helical Gears Double helical gears Herringbone gears

Axial thrust in helical gears

Bevel Gears
y Conical form y Intersecting shafts (Mostly at 90) y Straight Bevel gears y Teeth are radial y For low speed y Spiral bevel gear y Teeth are arc y For high speed

Bevel Gears
Straight bevel gears Spiral bevel gears

Bevel Gears
y Animation

Rack and pinion

y Gear of infinite radius is y Involute for circle with infinite radius becomes straight

line

Worm and work wheel

y Very high speed reduction and force/torque increment

Internal Spur Gear

y Compact drives y Large contact ratio y Less sliding, less wear

Gear Terminology

Law of gearing
y Common normal at point of contact should pass from

pitch point for constant velocity ratio

Involute Profile

Involute gear meshing

Cycloidal Profile

Cycloidal gear meshing

Involute vs Cycloidal profile

y Involute Gears y Easy to manufacture y Has single profile y Constant pressure angle y Change in centre distance doesn t affect velocity ratio y Interface can occur, Undercut is necessary y Has radial flank, hence weaker teeth y Concave surfaces in contact, hence more wear y Has universally replaced the cycloidal profile

Involute vs Cycloidal profile

y Cycloidal Gears y Difficult to manufacture y Has two profiles y Pressure angle is not constant y Change in centre distance affects velocity ratio y Interface cant occur, Undercut is not necessary y Has spreading flank, hence stronger teeth y Concave surface in contact with convex, hence less wear

Gear trains
y To achieve high increment/decrement in

force/torque/speed y Power remains constant and above parameters vary

y Types y Simple gear trains y Compound gear trains y Reverted gear trains y Planetary gear trains

Simple gear train

y Has one gear per shaft y Speed ratio Na/Nd = Tb/Ta * Tc/Tb * Td/Tc

= Td/Ta
A B C D

Compound gear train

y For high speed ratio y Speed ratio N1/N2 = T2/T1 y N3/N4 = T4/T3

N3=N2 N1/N2 * N2/N4 =N1/N4 So N1/N4 = T2/T1 * T4/T3 Speed of Driver/Follower =Product of teeth of Followers/Drivers

Reverted gear train

y Output and input shafts are on same shaft y 2-3 gears are on same shaft y Equivalent to compound train y r1 + r2 = r3 + r4 y T1 + T2 = T3 +T4

Epicyclic gear train

y Axes of a gear, rotates about another gear y If arm is fixed, its normal gear train

Condition Fix the arm. Rotate gear 1, one revolution clockwise Wheel 1 rotated m revolution Add n revolutions

Arm 0 0 n

Gear 1 +1 m m+n

Gear 2 -T1/T2 -m * T1/T2 n m * T1/T2

Planetary gear trains

Couplings
y Rigid or fast coupling y Muff coupling y Flange coupling y Does not permit axial misalignment y Non Rigid couplings y Connect shaft not in alignment y Pin type flexible coupling y Oldhalm coupling y Hook s joint

Muff coupling
y Uses key

Split muff coupling

y Enhanced sleeve coupling y Two halves connected with bolts y Heavy duty y Can be easily fitted or refitted

Flange coupling
y Most widely used y Medium to heavy duty y Need space y Unprotected/protected

Bush pin type flange coupling

y Modified flange coupling y Cushioning effect y Permit axial movement

Oldham coupling
y Permits shaft offset

Universal coupling/hook joint

y Permits angular misalignment

Clutches
y Permits connect or disconnect between shafts y Can provides partial transmission of power y Between engine and gearbox y Types of clutches y Positive: engage/disengage y Friction: provide partial power transmission, generate heat

Jaw clutch
y Jaw and toothed type clutch

y Spiral jaw clutch

Disc clutch
y Less heating, limited power, y Handle shock, y Handle acceleration y Uses Spring force to connect y Can be multidisc

Continue clutch

Cone clutch
y Less axial force needed

Centrifugal clutch

Keeps driving element unloaded till it is running at enough speed

Brakes
y Frictional resistance to stop machine motion y Used in automobile, lift, hoist y Converts kinetic energy into heat y Difference between Clutch and Brake y Types of mechanical brakes y Block or shoe brake y Band brake y Band and block brake y Internal expanding brake

Block or Shoe brake

y Railway wheels

Band brake
y Steel and with friction lining, ropes, leather y Hoist, Merry go round

Band and block brake

y Combination of band and block brakes

Internal expanding shoe brake

Disc brake

Dynamometers
y Measure the power transmission y Measure torque y Measure speed by tachometer y Absorption type
y y

Dissipate the energy Used for automobile engines, motor, turbines Does not absorb power Used in marine engines

y Transmission type
y y

Prony brake dynamometer

y Older design y Generates more heat and friction

y Lets calculate

Rope brake dynamometer

y Differential reading for torque