Syllabus

Part A: Mechanical Elements

Function, sketch, description and uses of shaft, axle, key
(parallel key), coupling, (rigid flange), bearing (ball), clutch
(single plate clutch), brake
Part B: Power transmission devices
Construction, working, comparison and applications of: Belt
drive (flat and V-belt), chain drive and spur gear drive
arranged with simple gear train.

Part A
Mechanical Elements
Syllabus
Function, sketch, description and uses of
shaft, axle, key (parallel key), coupling,
(rigid flange), bearing (ball), clutch (single
plate clutch), brake

Introduction to machine
Input
(source of
energy)

Machine
(arrangement
of elements)

Output
(prescribed
task)

Device consisting of various elements arranged

together so as to perform the prescribed task to
satisfy human needs.
Examples- pump set, I.C. engine, turbine, screw
jack, C-clamp etc.

Introduction to machine elements

It is individual part or component of a machine which performs
specific task.
Machine

E1

E2

E3

E4

Functions of machine elements are holding, supporting,

transforming.
Types of machine elements
1.
2.
3.

Holding- Axles, nuts and bolts, cotters, rivets, clamps

Supporting- Axle, bearing, brackets, body or frame
Power transmitting- shafts, pulleys, belts, sprocket, chains, gears etc.

Shafts
Rotating member usually of circular C/S used to
transmit power or motion.
For this purpose, various rotating members such as
gears, pulleys, sprockets etc. are mounted on it.

Fig. Shaft
Types of shafts
1. Transmission shaft
2. Machine shaft

Types of shafts
1. Transmission shaft
M

G
G

Machine

Fig. Transmission shaft

Used to transmit power between the source and the machines

absorbing power.
They carry machine elements like pulleys, gears, flywheels, etc.
These shafts are subjected to bending and torsional moment.

Types of shafts
2. Machine shafts

Spindle
Drill

Fig. machine shaft (drilling machine spindle)

They form an integral part of the machine itself.
They are also subjected to bending and torsional moment.
For example: Cam-shaft, crankshaft, machine spindle, etc.

Axle
An axle is a non-rotating or stationary machine
element which carries no torque.
It is used to support the rotating machine
elements like pulleys, brake drum, wheels, etc.
Though it is similar to shaft, it does not transmit
torque; but it is subjected to bending moment
only.
Axle
W
h
e
e
l

Comparison between shaft and axle

Sr. No.
Shaft
1.
Rotating element of a
machine
2.
Subjected to bending and
torsional moment
3.
Used to transmit torque
and support rotating
elements.
4.
for. example: Machine
shaft, transmission shaft

Axle
Non-rotating or stationary
element
Subjected to only bending
moment
Used to support rotating
elements.
For example: front axle in 4wheelers, 2- wheelers.

KEYS
A key is the piece inserted in a axial direction between a shaft and hub to prevent
relative rotation but allow sliding movement along the shaft if required.
Keys are temporary fastening and are always made of mild steel because they are
subjected to shearing and compressive stresses caused by the torque they
transmit.
a keyway is the groove cut in the shaft or hub to accommodate a key. Key ways
can be milled horizontally or vertically .

KEYS
Functions:
To prevent the relative motion between the shaft and the hub of rotating
element like : gear, pulley, or sprocket.
To transmit the torque from the shaft to the rotating element or vice-versa.
Keyway is a slot in a shaft and a hub of the rotating element to accommodate a
key.
It is inserted between the shaft and the hub of the rotating element so as to
prevent the relative motion between them.

Materials for key:

Plain carbon steels
Alloy steels.

Types of keys
Saddle keys

Hollow saddle key

Flat saddle key

Sunk keys

Taper sunk keys

Parallel sunk keys
Father keys
Woodruff key (adjustable key)

Taper sunk key

Round keys

Taper sunk key

Parallel pin
Taper pin

Tangent keys
Splines

Gib-headed key

Woodruff key

Kennedy keys consist

of two tapered
square keys placed
90 apart.
Applications :
Kennedy keys are
used in heavy duty
industrial
applications.

A round key is a
straight pin of
circular
crosssection, fitted into
a common hole
drilled
at
the
interface of shaft
and hub

Applications :
Round keys and
taper pins are
commonly used for
low power drives.

A taper pin is a pin of

circular cross-section,
fitted into a common
hole drilled through
the hub and shaft,
which
is
perpendicular to the
axis of the shaft.

COUPLING
Coupling is the mechanical element used to connect two
shafts of a transmission system and transmit the torque
from one shaft to another.

Shaft 1 (driving) Shaft 2 (driven)

Fig. Coupling

Functions of Coupling
It connects the shafts of two different units
such as an electric motor and machine.

It introduces mechanical flexibility between

two connected units and tolerates small
misalignment between the connecting shafts.
It reduces the transmission of vibrations and
shocks between two connected units.

Requirements of good coupling

It should transmit the full power from one shaft to
another.
It should keep the shafts in perfect alignment.
It should absorb the slight misalignment that may be
present between the driver and drive shaft.
It should be easy to connect and disconnect.
It should have no projecting parts.

Types of Couplings
Rigid coupling
Muff or sleeve coupling
Split muff or clamp coupling
Flange coupling

Flexible Coupling
Bushed-pin type
Universal or Hooke's
Oldhams coupling
Bushed-pin
type

Types of couplings
Oldham's coupling

Universal coupling

Rigid Couplings
Rigid couplings are used to connect two shafts which
are perfectly aligned.

These couplings are not capable of tolerating any

misalignment between two shafts.
These couplings are not capable of absorbing shocks
and vibrations.
These are simple and inexpensive.

Protected type rigid flange coupling

It consists of two flanges:
one keyed to the driving shaft
and other to the driven shaft.
One of the flange has projected
portion and other has a
corresponding recess. This helps
to bring two shafts in line and
maintain the alignment.
The two flanges are coupled
together by means of bolts
and nuts. The number of
bolts used are generally
three, four or six. The two
keys are staggered at right
angles
along
the
circumference of the shafts.
The flanges are made of
cast iron, cast steel, or steel.

The torque is transmitted from the driving shaft

to the left side flange through the key. It is then
transmitted from the left side flange to the
right side flange through the bolts. Finally, it is
transmitted from the right side flange to the
driven shaft through the key.
Advantages
1. The flange coupling is easy to assemble and
disassemble.
2. It has high torque transmitting capacity.
Disadvantages
1. The
flange
coupling
cannot
tolerate
misalignment between driving and driven
shafts.
2. It requires more radial space.
Applications
The flange coupling is used for connecting
electric motor to pump or compressor.

Protected type rigid flange coupling

Bearings
Bearing is a machine element which supports another
moving machine element called as journal.
It permits a relative motion between the contact surfaces
of the members.
Due to relative motion between the contact surfaces,
there is friction and wear hence lubricant is required.
The commonly used lubricants are vegetable oil, silicon
oil, grease, etc.
Bearing

Function of a Bearing
The main function of a rotating shaft is to transmit power
from one end of the line to the other.

It needs a good support to ensure stability and

frictionless rotation. The support for the shaft is
known as bearing.
The shaft has a running fit in a bearing. All bearing are

provided some lubrication arrangement to reduced friction

between shaft and bearing.

It also sustains the forces acting on the shaft or axle and

transmits them to the frame of the machine.

Bearings are classified under two main

categories:
Plain or slider bearing : In which the rotating shaft has a sliding
contact with the bearing which is held
stationary . Due to large contact area
friction between mating parts is high
requiring greater lubrication.

Rolling or anti-friction bearing : Due to less contact area rolling friction is

much lesser than the sliding friction ,
hence these bearings are also known as
antifriction bearing.

Rolling contact bearing- Ball bearing

Major parts:

Outer race
Inner race
Rolling element
Separator or retainer

Types of ball bearings

1.
2.
3.
4.

Single row deep-groove ball bearings

Double row deep-groove ball bearings
Angular contact bearings
Self-aligning bearings

Roller bearing

Clutches
Clutch is a mechanism to transmit rotary motion from one
shaft (driving shaft) to another coincident shaft, (driven
shaft), as and when required, without stopping the driver
shaft.
Clutches are also required to disengage the drive from
engine to gearbox for changing the gears.
During slowing of vehicle or stopping, the clutch is used to
disengage engine from drive wheels and enable smooth
stopping of vehicle.
Since clutch is of friction material, it also takes care of
speed and torque variation from engine crankshaft to
gearbox input shaft.

Functions of the clutch

When clutch is engaged (clutch pedal position-up), the
clutch transmits maximum power from engine
crankshaft to gearbox input shaft.
When clutch is engaging (clutch pedal position-moving
up), the clutch accommodates for minor slippages and
hence provides smooth drive transmission without
jerks.
When clutch is disengaged (clutch pedal position-down),
the clutch allows driver to shift the transmission in
various gear positions (first, second, third, etc.)
When clutch is disengaged (clutch pedal position-down),
the engine can be cranked freely without transmitting
the drive to wheels.

Types of Clutches
1. Friction clutches
These clutches work on the friction principle that
when two independent disc have relative motion
between them, friction is caused.
Friction clutches are the most commonly used
clutches.

2.

Positive clutches
These clutches are used when positive drive is
required.
These type of clutches are used in sprocket wheels,
gears, pulleys, etc.

Single Plate Clutch

Single plate is the most commonly used type
of clutch on automobiles.
It provides quicker disengagement.
It consists of clutch disc, pressure plate, and a
cover assembly which are bolted to the
engine flywheel.

Single plate clutch

Major
components

Flywheel
Friction plate
Pressure plate
Thrust spring
Release lever
Clutch cover
Clutch shaft
Thrust bearing

Advantages & Disadvantages

Advantages :

Simple design of construction and working.

Better heat dissipation from single plate.
Gear changing with single plate clutch is easier.
It has better torsional vibration absorbing capacity.

Disadvantages :
For higher power transmission, the surface area of
clutch plate increases and thereby increasing the
overall size of clutch.
Clutch pedal force required is higher.

Brakes
Brake is a device with the help of which artificial
frictional resistance is applied to a moving machine
member, in order to stop or retard the motion of a
machine.
While performing this function, the brake absorbs
either kinetic energy of the moving member or
potential energy given by objects being lowered by
cranes, elevators, etc.
The energy absorbed by the brake is dissipated in the
form of heat in the surrounding air, so that excessive
heating of the brake lining does not take place.

Types of brakes
Mechanical
brakes

Hydraulic
brakes

Brakes

Magnetic
brakes

1.
2.
3.
4.

Block brakes
Disc brakes
Band brakes
Internal or
external shoe
brake

Electric
brakes

Disc Brake
Disc brakes are more efficient and now-a-days
being adopted on large scale in the automotive
segment.
It consists of a rotating brake disc mounted on the
wheel and two friction pads positioned on either
side of the disc.
The pressing of the stationary brake pads on the
revolving disc causes friction, resulting in braking.

Advantages & Disadvantages

Advantages :
The operation and assembly of disc brake is much
simpler.
As the friction pads are flat, the wear and tear is
uniform.
Heat dissipation is faster.

Disadvantages :
The overall system cost is higher due to hydraulic
caliper and fluid lines.
The frictional area of pads is less, thereby requiring
high pressure intensity fluid.

Part B
Power transmission devices
Syllabus
Construction,
working,
comparison
and
applications of: Belt drive (flat and V-belt), chain
drive and spur gear drive arranged with simple
gear train.

Introduction
Usually power is transmitted by means of belts,
ropes, chains and gears.
For large distances, belt, ropes and chains are used
and for smaller distances, gears are used.
Belts, ropes and chains are flexible type of
connectors.
Owing to slipping and straining action, belts and
ropes are not positive drive.
On the other hand, chains and gears are positive
drives (rigid).

Belt drives
It consists of 3 elements:
Driving or head pulley
Driven or tail pulley
Endless belt
Power is transmitted because of
frictional grip.
Belt drive

Speed ratio of belt drive:

speed ratio = speed of driving pulley/speed of driven pulley
= n/N
= D/d
= (D+t)/(d+t)
Where, n and N = speed of driving and driven pulley in RPM
d and D = diameters of driving and driven pulleys in mm
t = thickness of belt in mm.

Types of belts
Materials used for belts

Sr. No.

Type

Leather
Cotton
Rubber
Balata

Characteristics

1.

Flat belt

2.

V-Belt

Trapezoidal C/S
Large amount of power and pulleys are nearer
Pulleys are provided with groove

3.

Circular
belt

Rectangular C/S
Moderate amount of power
Used when pulleys are not more than 8 m apart
Crowned pulleys are used

Circular C/S
Large amount of power
Pulleys are more than 8 m apart
Pulleys are provided with groove

Comparison between flat and V-belt

Sr.
No.

Parameter

Flat belt

V-belt

1.

Cost

Low

Higher

2.

Maintenance

Low

Higher

3.

Multiple speed ratio

Can be used

Cannot be used

4.

Simplicity of design

Simple to design

Complex

5.

Efficiency

Higher

Lower

6.

Long center distance

Can be used

Short distances

7.

Working environment

Dusty and abrasive

atmosphere

Dust free environment

8.

Power trans. Capacity

Lower

High

9.

High speed reduction

Upto 4:1

Upto 7:1

10.

Overall size of drive

Bigger size

Compact size

11.

Use of multiple belts

Restricted for single belt Multiple belts can be used

12.

Smoothness of drive

More noisy at higher

speeds

Relatively smooth

Types of flat belt drives

Open belt with idler pulley drive

Open belt drive

Crossed belt drive

Compound belt
drive

Advantages and disadvantages of belt drive

Advantages
Can be used for long Centre distances
Absorb shocks and vibrations
Lubrication is not required
Not affected due to dirt and dust
Do not require precise alignment of shaft and pulley

Disadvantages
Low power transmitting capacity
Can not be used at extremely high speeds
Shorter life and more space as compared to gear drive
Not positive drive

Chain drive

To avoid slipping, chain drives are used

Chain drive consists of chain and sprocket
Chains are made up of no of rigid links hinged together
Sprockets have projecting teeth of special profile and fit into the
corresponding recesses in the chain links.
This drive is commonly used to transmit motion from shafts having
shorter centre distances.
Used in bicycles, motor cycles, conveyors, road rollers, rolling mill,
agricultural machinery, etc.

Types of chain drive

1. Hoisting and hauling (crane) chains
Used for hoisting purposes
Operate at maximum velocity
Links may be of oval or
square shape
Oval shape is commonly used

2. Conveyor (tractive)chains
Used for elevating and conveying
materials
Operate at moderate speed
Chains are made of CI
Links may be of hook joint or closed
joint type

Advantages and disadvantages of

chain drive over belt drive

Advantages

No slip hence perfect speed ratio

Less space in width than belt drive
More transmission efficiency
Offers/provides less loads on the shafts
Can be operated under low/high temperatures
More power transmitting capacity

Disadvantages
More cost
Needs accurate mounting and careful maintenance
Noisy operation

Comparison between chain and belt drive

Sr.
No.

Parameter

Chain drive

Belt drive

1.

Drive elements

Chain and sprockets

Belt and pulleys

2.

Type of drive

Positive

Non-positive

3.

Power transmitting
capacity

High

Low

4.

Transmission efficiency

High

Low

5.

Space requirement

Less

More

6.

Operating conditions

Can operate in
adverse conditions

Can not be operated

in adverse conditions

7.

Lubrication

Required

Not required

8.

Operating noise

More

Less

9.

Precise alignment

Required

Not required

10.

Manufacturing cost

More

less

Gear drive
Gears are defined as toothed wheels
which can transmit power and motion
from one shaft to another shaft by means
of successive engagement of teeth.
It is a positive drive and used for smaller
centre distances.
Spur gear drive

Smaller gear is called as pinion and larger gear is called as gear.

Speed ratio = speed of pinion/speed of gear
= np /ng
= dg /dp
= Zg /Zp
Where , np ,ng = pinion and gear speed in RPM
dg and dp = diameters of gear and pinion
Zg and Zp = no of teeth on gear and pinion

Spur gear drive

Spur gears are used to transmit motion
between two parallel shafts.
Simplest of all gears and easiest in
production
Teeth of spur gear are cut along the
periphery and parallel to the axis of gear.
They are made of steel, brass, other
metals and plastics.
Advantages
Spur gears are easy to manufacture
They are made in variety of sizes from less than 25 mm to several cm in
diameter.
Less expensive
Applications : commonly used in
High efficiency (upto 98 %)
machine tool gear box, watches, etc.

Disadvantages

Not used for high speed applications

Noisy operation.

Gear train
A gear train is a combination of two or more gears
which is used for power transmission.
It is used to obtain large speed reduction within a
small space.
The nature of gear train used depends upon the
required velocity ratio and the relative positions of
the axes of the shafts.
They are commonly used in various machines,
automobiles, clocks, ships, watches, etc.
Different types of gear trains are simple gear train,
compound gear train, reverted gear train and
epicyclic gear train.

Simple gear train

Simple gear train

If only one gear is mounted on each shaft and there is no relative motion
between their axes then it is called as simple gear train.
If the distance between the two gears is large, then the intermediate gears
are used.
If number of intermediate gears are odd then the motion of driver and
driven gear is same.
Similarly, if the number of intermediate gears are even then the motion of
driver and driven gear is opposite.

Comparison between gear drive and

belt drive
Sr.
No.

Parameter

Gear drive
Gear and
pinion

Belt drive

1.

Drive elements

Belt and
pulleys

2.

Power transmitting capacity High

Low

3.

Space requirement

Less

More

4.

Lubrication

Required

Not required

5.

Operating noise

Moderate

Less

6.

Precise alignment

Required

Not required

7.

Manufacturing cost

More

Less

8.

Type of drive

Positive

Non-positive