Design report

ME308

Authors:
1). Nageswararao E, 16XJ1A0324
2). Sandeep Reddy, 16XJ1A0340
3). Shiva Sai Reddy, 16XJ1A0343

Objective:
To design a floor-based machine that can lift
20kg through a height of 5m. We assume that the
load accelerates very slowly during the lifting. Also,
the rope is assumed to not slack anywhere.

Methodologies:
The design was based on empirical relations
that generate standardised dimensions for the
components. Code was then used to validate the
safety of design.

Results of design:
Cable:
1) First, we select a suitable type of rope from Table
1.
2) We find the design load by assuming a factor of
safety 2.5 times the factor of safety given in Table 2.
3) We find the diameter of wire rope by equating the
tensile strength of the rope selected to the design
load.
4) We find the diameter of the wire and area of the
rope from Table 3.
5) We find the various stresses in the rope and
compute the effective stresses during normal
working and while starting.
a) Normal working conditions

where

b) At start

where
6) We then find the actual factor of safety and if it is
satisfactory, the design is considered safe.
(Nomenclature for rope at mentioned at the end)

Nomenclature for rope design:

W = Load lifted
w = Weight of the rope
Er = Modulus of elasticity of the wire rope
dw = Diameter of the wire
D = Diameter of the sheave or drum
A = Net cross-sectional area of the rope

Source:
A Textbook of Machine Design by R.S. Khurmi and
J.K. Gupta.

Result:
Rope type – 6 x 19 steel wire rope
Length = 5.5 m
Diameter = 2.43 mm

Design of winch drum:

Winch drum design is based on the dimensions of
the rope previously obtained.
Standard parameters for a safe drum are calculated
based on the following expressions.
Nomenclature for drum:
r: groove radius
p: pitch diameter
h: groove depth
D: diameter of the drum (= 35*diameter of rope,
arrived at by literature survey)
Lg: grooved length (= 20*p)
Lu: ungrooved length on each side (=1/2(shank
diameter of hook) + rope diameter)

Result:
Material - Cast Iron
Diameter = 85.16 mm
Pitch diameter = 2.8 mm
Groove depth = 0.608 mm
Groove radius = 1.29 mm
Grooved length = 56 mm
Ungrooved length = 10 mm (on each side)
Total length = 76 mm

Shaft:
Material : 30C8, carbon steel
Yield strength, 𝑠𝑦𝑡 : 4𝑥108 𝑃𝑎
Factor of safety, FOS : 2
0.5𝑠𝑦𝑡
Max. permissible stress, 𝜏𝑚𝑎𝑥 = =108 𝑃𝑎
𝐹𝑂𝑆
From previous results, diameter of winch drum,
𝐷𝑤 = 0.09𝑚
𝐷𝑤
Transmitted torque, 𝑀𝑡 = 𝑥20𝑥9.81 = 9𝑁 − 𝑚
2
Correction factor for torsion, 𝑘𝑡 = 1
Based on maximum shear stress theory,
16𝑀𝑡 𝑘𝑡
𝜏𝑚𝑎𝑥 =
𝜋𝑑 3
From which, we obtain
𝑑𝑠ℎ𝑎𝑓𝑡 ≈ 8𝑚𝑚

Square key:
From previous, 𝑑𝑠ℎ𝑎𝑓𝑡 = 8𝑚𝑚
Torque, 𝑀𝑡 = 9𝑁 − 𝑚
Material used: 50C4, carbon steel
Yield strength, 𝑆𝑦𝑡 = 4.6𝑥108 𝑃𝑎
Factor of safety, FOS : 3
According maximum shear stress theory,
𝑆𝑦𝑡
𝜏𝑚𝑎𝑥 = = 0.767𝑥108 𝑃𝑎
2𝐹𝑂𝑆
𝑑𝑠ℎ𝑎𝑓𝑡
According to industry practice, 𝑏 = ℎ = = 2𝑚𝑚
4
2𝑀𝑡
Then, the length of the key, 𝑙 = = 15𝑚𝑚
𝜏𝑑𝑏