KWA OVERSEER GRADE 3

MECHANICAL ENGG TOPICS

Expected Topics
• Basics of Thermodynamics
• IC Engine
• Machine Tools – Lathe , milling machine , shaper, slotting &
Planning machine
• Machine Drawing – Fasteners, Nut bolt & Washer , screw threads ,
key & key ways , Welded & Rivetted joints , Pipe fittings, coupling,
etc..
• Power Transmission – Gear drive , belt drive , chain drive

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BELT DRIVES
 BELT DRIVES
• Flexible machine elements
• Absorb good amount of shock & vibrations
• Some degrees of misalignments are permitted between driver &
driven pulley
• Long distance power transmission
• Belt or ropes are used to transmit power from one shaft to other by
using a pulley which rotates at same speed or different speed.

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 BELT DRIVE
• Driver pulley – power source
• Driven pulley – moves with the
help of driver pulley
• Power transmission with the
help of friction between two
pulleys and belt
• Belt – upper side – slack
• Lower side – tight

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• Belt drives operate on friction principle
• Friction between belt & pulley is responsible for transmitting power
from one pulley to other
• Due to friction , tension on both sides of the belt are not equal.
• There is a slack side & tight side
• Slip occurs in belt drive
• Negative power transmission system

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Types of belt drives

• Open belt drive

• Closed or crossed belt drive
• Fast and loose cone pulley
• Stepped cone pulley
• Jockey pulley drive

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OPEN BELT DRIVE
• Both pulleys rotate in same
direction
• Connecting Parallel shafts
• If the shafts are having more
distance between driver and
driving pulley then upper side
will be slack side and the lower
side will be the tight side.

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 CROSSED BELT DRIVE
• Known as CLOSE BELT DRIVE
• Transmitted power is more
• Both pulleys rotate in opposite
direction
• Long Belt length
• It can not run faster-If so then
rubbing between belts may result in
wear and tear.
• Shaft centre to centre distance – 20*
width of belt

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 Fast and loose cone pulley
• Used where the driven pulley or
shaft is to be started or stopped
when ever desired without
interfering with the driving shaft
• fast pulley is mounted on a shaft
with keyed joint and same speed of
machine
• loose pulley runs freely on the
shaft and it is incapable of
transmitting any power.

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Stepped cone pulley/speed cone drive

• Known as speed cone.

• there are more pulleys
attached of different diameter
one adjacent to another.
• used where they have to
change gear or speed of driven
shaft
• Lathe, Drilling, etc..

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JOCKEY PULLEY
• Idler pulley
• helps to increase the angle of
contact of the belt
• belt tension is increased
• drive provides a high-velocity
ratio.
𝐷
• X > 3D Or >6
𝑑

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Guide pulley
• Convert Horizontal drive to vertical drive

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SLIP & CREEP
• Slip --- insufficient frictional grip between pulley and belt.
• Slip is the difference between the linear velocities of pulley
and belt. ...
• CREEP - Uneven extensions and contractions of the belt when
it passes from tight side to slack side
• There is relative motion between belt and pulley surface, this
phenomenon is called creep of belt.
• Elastic stretch

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Types of Belt

Belt has been categorized into four types which are:

● Flat belt

● V belt
● Circular belt
● Timing belt

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 Flat Belt
• Rectangular cross-section.
• Moderate Power transmission
• used where low power is required and
speed is more.
• Generally, the shaft distance is not more
than 8 meters.
• efficiency of around 98 percentage
• little noise

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V belt

• V belts are in the trapezoidal

cross-section.
• Used with grooved pulleys
• V belts are used where shaft
distance is less than 2 meters
• used for moderate speed and high
power.
• Included angle in v belt is usually
30-40 degree
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 Circular belt
• It is a circular cross-section.
• Circular belts are used where more
than 8meter shaft distance
• Used with grooved pulley
• high power transmission.
• absences of vibration and noise

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Timing belt

• Toothed belts/ no slippage

• Timing belts are mainly used
inside IC Engine system to
transmit power.
• Timing belts are a positive drive.

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 Belt Material
• Leather belt
• Rubber belt
• Cotton or Fabric belt
• Plastic belt
• Balata belt

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 Leather belt

• more expensive
• one layer of leather is joint to another layer to become stronger
and increase the thickness of the belt.

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Cotton or Fabric belt

• mostly used in farm machinery and belt conveyor.

• cheaper and best suited for warm climates and a damp
atmosphere.

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Rubber belt

• made up of fabric.
• used in sawmills, paper mills and more

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Plastic belt
• made up of plastic sheets and rubber layers.
• it can design almost at any size.

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Balata belt
• Balata belts are similar to rubber type belts
• stronger than rubber belt.
• balata gum is used to stick it.
• Waterproof type belt and has a high resistance to acidic,
alkaline material
• used for food packaging conveyor.
• not used for high temperatures because balata becomes sticky
gum at a higher temperature.

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BELT DRESSING
• Improve gripping
• Powdered resin is added

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CROWNING
• A crowned pulley is a pulley that has a slight hump in the middle,
tapering off ,slightly towards either edge
• Outer surfaces of pulley is finished with little convexity
• Top portion called crown

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Centrifugal tension in belts
• Since the belt is continuously runs over the pulley, some centrifugal
force is produced whose effect is to increase the tension on both
sides.
• This tension is called centrifugal tension
• Condition For maximum power transmission, Tc = T/3
where T = maximum tension
Tc = centrifugal tension

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VELOCITY RATIO FOR BELT DRIVE
VELOCITY RATIO
𝑵𝟐 𝑫𝟏
=
𝑵𝟏 𝑫𝟐

N1 =velocity of shaft 1
N2=velocity of shaft 2
D1= Dia of of shaft 1
D2= Dia of of shaft 2

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Power transmitted by a belt
Power transmitted by a belt , P = (T1-T2) V
v is the velocity of belt in m/s.

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Initial tension in the belt
T0 = Initial tension in the belt,
T1 = Tension in the tight side of the belt,
T2 = Tension in the slack side of the belt, and

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Ratio of driving tension for flat belt

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 c

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 c

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 d

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 a

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 c

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 a

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 a

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 b

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Usually, outer surfaces of pulley is finished with little convexity, which is
known as
Flank of pulley Effective diameter of pulley
Crowning of pulley Crackness of pulley

Driver and driven pulleys move in opposite directions in

Open belt drive Cross belt drive
Quarter twist drive using jokey pulley

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Which one of the following belt materials can withstand acidic and
wet condition
Leather ballata rubber cotton

The V-belts are particularly suitable for _____________ drives.

a) short b) long
c) medium d) none of the mentioned

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CHAIN DRIVES
• Power transmission method
• Positive power transmission
• Used in power transmission on
vehicles- bicycles, motorcycles,
etc…
• Endless chain link meshes with
toothed sprockets
• Centre to centre distance
moderate
• Lubrication required

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SPROCKETS
• Toothed wheel in chain drive
• Driver and driven sprockets will
rotate in same direction
• Link of chain meshes with teeth
of sprockets

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KEY & KEYWAYS

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 KEYS
• Machine element used to connect a
rotating machine element
• Prevent the rotation of shaft inside the
hub
• Key placed on the groove cut on the shaft
called KEY SEAT
• Groove cut on hub – KEYWAY
• Keys are Temporary Joints

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➢It is used to transmit
torque from shaft to
hub.
➢It is always subjected to
shearing and crushing
stress, so its always
made of Steel

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 KEYS

SUNK SADDLE TANGENT ROUND

SPLINES
KEY KEY KEY KEY

1.Rectangular
Sunk Key 1. Tapered
2. Square Sunk 1.Flat Saddle Round
Key Key Key
3.Parallel Sunk
Key
2.Hollow 2. Straight
4. Gib Head Key Saddle Key Round
5.Feather Key Key
6.WoodRuff Key
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SUNK KEY
❑It may be either Rectangular or Square in Cross section.
❑ keys are provided partly in the shaft and partly in the hub.
❑It is suitable for Heavy Load Applications
Types - RECTANGULAR KEY
- SQUARE KEY
- PARALLEL KEY
- GIB HEAD KEY
- FEATHER KEY
- WOODRUFF KEY

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Design of sunk key
• D- Dia of shaft
• Length of the Key = 1.5 D
• Width of the key = D/4
• Thickness of the key = D/6
• Taper 1: 100

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RECTANGULAR KEY
• In this the cross section of key is rectangle
• Taper in Key is 1in100 on top side only and key is parallel to shaft
axis
• used for preventing rotation of gears and pulleys on the shaft

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SQUARE KEY
• Width & thickness of key are equal (D/4)

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 PARALLEL KEY
• Key may be of rectangular or square section uniform in width and
thickness throughout
• It is taper less
• Used where the rotating element is required to slide along the
shaft.

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GIB HEAD KEY
• This key is usually provided with a head called gib-head
• This type head is provided for the easy removal of key.
• It is used when the mating parts are to be separated occasionally for
the purpose of repair
• Thickness at the large end = D/6
• Width of the key = D/4

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FEATHER KEY
• key permit relative axial movement between shaft & hub

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WOODRUFF KEY
• The Woodruff key is a semi-circular disc and fits into a circular recess in
the shaft.
• It is an easily adjustable key
• These woodruff keys are mostly used in machine tools and automobile
shafts.

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SADDLE KEY
• Saddle keys are fixed into the keyway of hub only
• Power transmission is achieved by the friction between shaft
and key.
• It is used for light duty applications and low power transmission

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(a)Flat Saddle Key:
✓Tapered key which fits in the keyway of hub and is flat on the
shaft.
✓It is used for light load applications.
✓It is used for Temporary Fastening

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(b) Hollow Saddle Key
✓It is a taper key which fits in the keyway of hub
and the bottom of key is shaped to fit in the
curved surface of the shaft.
✓It can be used for comparatively larger load than
flat saddle key.
✓This key have larger friction between key and the
shaft due to curved surface at the bottom.

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 Tangent keys (kennedy’s key)

• It fits in both shaft and hub.

• It is fitted as a pair of right angles tangential
to the shaft.
• Each key is to withstand torsion in one
direction only.
• Used for large heavy duty applications

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 ROUND / CIRCULAR KEYS
• Keys of circular cross section called as round keys and it is
drilled partly in the shaft and partly in the hub.
• It is used for light power transmission purposes.
• Two Types of Round Keys.
(a) Tapered Round Key
(b) Straight Round Key

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There keyway may be drilled or reamed after the mating parts
have been assembled

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 ANS A

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 ANS C

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 ANS A

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 ANS D

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COUPLINGS & COTTER

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 COUPLINGS
It is a power transmission element which is used to transmit
power or torque from one shaft to another shaft

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ADVANTAGES OF COUPLING
✓ It is used to connect driver and driven shaft.
✓ Introduce a protection against overload
✓ It provides misalignment of joining shafts.
✓ Used to alter vibration characteristics of rotating element.

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 TYPES OF COUPLINGS

COUPLING

RIGID COUPLING FLEXIBILE COUPLING

• Bushed Pin Flexible coupling

• Sleeve/ Solid Muff Coupling
• Universal Coupling
• Split Muff Coupling
• Oldham’s Coupling
• Flanged Coupling

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 TYPES OF COUPLINGS
1. RIGID COUPLING
It is used to connect two shafts which are perfectly aligned
1.Sleeve /Solid Muff Coupling
2. Split Muff Coupling
3. Flange Coupling

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Sleeve /Solid Muff Coupling
● Simplest type & Designed as a hollow shaft
● In this the end of two shaft to be coupled butt against each
other and a cast iron muff coupling envelopes it.
● It envelopes over the end of two shafts by Gib-head key.
● Outer Diameter of Sleeve , D = 2d +13 mm
● Length of Sleeve , L = 3.5 d
● Connect upto 30 mm dia shafts

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 Split Muff Coupling/ Clamp / Compression
Coupling:
❑ In this the muff is split into two semi
cylindrical halves which are held together by
means of square headed bolt and nuts.
❑ Threaded holes are provided on the muff so
that the shaft can be joined with the steel
bolts (8 to 12 bolts are used)

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❑ Used for Heavy Load/Moderate speed applications.
❑ Coupling is done be Feather key.
❑ This type of coupling can be placed at anywhere on the shaft.
❑ Outer Diameter of sleeve , D= 2d+13
❑ Length of Sleeve , L= 3.5d

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 Flange Coupling
❑ It is the most common type of coupling used to
connect two shafts by means of two Flanges.

❑ It consist of two similar cast iron flanges to which

the shafts are keyed together with the help of taper
keys.

❑ Both Flanges are then tightly held together by bolts.

1. Shaft Diameter – d
2. Hub Diameter -2d
3. Length of Hub – 1.5d No: of Bolts used = 3 for ‘d’ up to 40mm
4. Pitch circle diameter of Bolt- 3d 4 for ‘d’ up to 100mm
5. Outside diameter of Flange – 4d 6 for ‘d’ up to 180mm
6. Thickness of Flange – 0.5d
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 TYPES OF COUPLINGS
Flange Coupling:
(a) Protected Type Flange Coupling

(b) Unprotected Flange coupling

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 TYPES OF COUPLINGS

FLEXIBLE COUPLING:

It is used to connect two shafts having both lateral and

angular misalignment.
These couplings are used when slight relative movement is
required or the axis of shaft run slightly out of line.

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 (A) Bushed Pin Type Coupling:
❑ It is the modified form of Flange coupling and in
this driving pin work as coupling bolts.
❑ Pin type coupling is most commonly used flexible
type coupling.
❑ Brass bushes and rubber covering is provided on
the driving pin to absorb shock and vibrations.
❑ It doesn’t transmit shock from one shaft to
another shaft.
❑ Used for slight misalignment of shaft.

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(B) Universal Coupling:
❑ It is used to connect two shafts whose axis
intersect an angle.
❑ It is used to connect the propeller shaft
with gearbox shaft and differential of an
automobile.
❑ It is also called Hooke’s Coupling.
❑ It will not work properly if the angle
between two shafts is more than 450.

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 Oldham’s Coupling
❑ It is used for connect two shafts whose axis
are parallel but not in line.

❑ It consist of two flanges with grooves and a

central floating disc
❑ The central floating disc have two projections
called as Tongues situated at right angle to
each other is inserted in between the flanges.
❑ These tongues slides in the grooves on flanges
and transmit the power.

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 COTTER JOINT
❑ A cotter joint, also known as a socket and spigot joint
❑ Cotter joints are used to join two rods or shafts that are coaxial
❑ A cotter is a flat wedge shaped piece of rectangular cross section. Its
width is tapered from one end to other end.

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❑Shafts that rotate and transmit torque cannot joined by Cotter
Joint.
❑Taper varies from 1 in 48 to 1 in 24.

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A

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 A

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 C

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 A

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 A

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 D

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 A

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 A

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 D

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 D

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 C

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 C

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Extra Topic – read
the notes
PIPE FITTING
• connect straight pipe or tubing sections of different sizes or shapes
• Provide a jointing method if 2 dissimilar piping materials are used
in the one system.
• Common pipe fittings are
Elbow, Tee , Cross, Reducer, Cap, Union

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 ELBOW

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 ELBOW
• change of direction, usually 90°
or 45°. • long radius is 1.5 times the
nominal diameter.
• When the two ends differ in
size - Reducing or Reducer • long radius - used to ensure
Elbow. smooth flow, reduce wear to
both product and piping and to
• Available in short radius or long
reduce the chance of getting
radius of types.
blockages
• Short radius elbows have a
center to end distance equal to
the nominal diameter

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 TEE
• Branch off the pipe at 90 degree
• Either combine or split a fluid
flow.
• A swept tee -the branch enters
the body at an arc and is used to
minimize the frictional losses
• A wye tee - the branch is stabbed
into the body at an angle and is
usually used where the branch is
a smaller diameter than the main
pipe

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 CROSS
• A cross has one inlet and three
outlets, or vice versa and like tees
come in equal and reducing forms.
• more expensive than two tees but
has the advantage of reduced space
• requires less labour to install.

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 REDUCERS
• used to join 2 different pipe sizes
together.
• Either concentric or eccentric.
• Eccentric reducer – horizontal
position
• Concentric reducer – vertical position

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 CAP & PLUG
• A type of pipe fitting which is liquid
or gas tight
• used to cover the end of a pipe.
• Cap – Internal thread
• A cap has a similar function to a
plug.
• Plug – external thread
• PLUG is used with internal threaded
pipes

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 COUPLINGS
• Connect two pipes
• Internal threads at both ends
• coupling is usually a permanent joint
• Requires the ability of being able to
rotate all the pipe to one side of it to
unscrew it

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 UNION
• union is similar to a
coupling
• It is designed to allow quick
and convenient
disconnection of pipes for
maintenance or fixture
replacement.

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THANK YOU