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Part II

Mechanical system
Introduction

Drive

1.
2.

Electric motor
I.C.E
Diesel Eng.
Benzene Eng.
3. E.C.E
Boiler
Steam Turbine
Gas Turbine
Jet Eng
4. Water power
5. Wind energy
6. Solar energy
7. Chemical energy
8. Tidal energy
9. Nuclear energy
10. Geothermal energy
11. Fossil Fuels

Connection

1-Coupling

Driven

Any Machine

2-Clutch
3-Break
4-Belt
5-Chain
6- Gear

Chapter 1
Drive
Drive may be one of the following
1. Electric motor
2. I.C.E ( internal combustion engine )

Diesel Eng.
Benzene Eng.
Four-stork engine

3. E.C.E ( external combustion engine )

Boiler

Fire tube boiler

Water tube boiler

Steam Turbine

Gas Turbine

Jet engine

4. Water power

Frances turbine

Pelton wheel

The power available in a stream of water is;

where:

P = power (J/s or watts)


= turbine efficiency
= density of water (kg/m)
g = acceleration of gravity (9.81 m/s)
h = head (m). For still water, this is the difference in height between the inlet and outlet
surfaces. Moving water has an additional component added to account for the kinetic
energy of the flow. The total head equals the pressure head plus velocity head.

= flow rate (m/s)

5. Wind energy

Wind Turbine Power Equation


WP = 0.5 x AD x SA x WV3 x CP

(HWP) Wind Power (w/hr)

AD (air density 1.23 kg/cu m)

SA (sweep area m^2)

WV (wind velocity m/s)

CP (coefficient of performance 0.25 for most systems)

6. Solar energy
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Solar collector

Solar cell

Solar reflector

7. Chemical energy
Dry battery
Wet battery
Rechargeable battery

8. Tidal energy

Maximum Tidal Energy, E = 2HQ kWh/yr,


Where
H is the tidal range (m)
Q is the tidal flow (m3/sec of seawater)
2 (2 tides)
9. Nuclear energy
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10. Geothermal energy

11. Fossil Fuels

Natural gas
Petrol oil
Wood
coal

Chapter 2
Coupling Clutch break
2-1 Terms
1. Coupling: device used for permanent connection of two
shafts, so that the two shafts are forced to run at equal speed.
2. Clutch: device used for connection of two shafts which
permits rapid connection and disconnection.
3. Brake: device used for deceleration of rotating bodies.
2-2 Coupling
Types of coupling are
1. Rigid coupling:
Rigid coupling applied only if
a) Both shafts have constantly the same.
b) The axial distance between the shafts is constant.
And can be used in the following shafts position

Some types of rigid couplings


a) Box coupling
The simplest coupling type.
Material: steel (e.g. st. 34, st .50)

Design rules
The pins are stressed on shear. And Maximum torque can be transmitted is

b) muff coupling DIN 115


Maximum torque can be transmitted
Z.. Number of bolts
Material: cast iron

c) Flanged coupling
For transmission of big torques

d) Flanged coupling, flanged integral with the shafts


Maximum torque can be transmitted
(

force acting in each bolt

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2. Self aligning couplings with no torque- elasticity


The can accommodate misalignments of shafts and / or variation of axial distance between the shafts.
Some types described below
a) Jaw coupling (accommodates variation of axial distance only)

b) Cardan joint (for angular misalignment)

3. Flexible couplings (self aligning couplings with torque-elasticity)


They accommodate small misalignments and reduce ( reduce and damp) torque shocks
a) Coupling with rubber sleeves

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Flexible-disk coupling
b) Periflex coupling
Both rigid parts of coupling are connected by rubber member

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4. Safety couplings
These coupling limit the transmitted torque, and when torque exceed the limit , the coupling will slip or
be disconnected.
a) Shearing pin coupling
Pins transmits torque and will break at a certain torque. It must be replaced before the coupling
is used again.

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2-3 CLUTCHES
Clutch is a machine member used to connect the driving shaft to a driven shaft, so that the driven shaft
may be started or stopped at will, without stopping the driving shaft. A clutch thus provides an
interruptible connection between two rotating shafts. Clutches allow a high inertia load to be stated
with a small power.

Mechanical Model
Two inertias I1and I2 traveling at the respective angular velocities I and 2, and one of which may be
zero, are to be brought to the same speed by engaging. Slippage occurs because the two elements are
running at different speeds and energy is dissipated during actuation, resulting in temperature rise. 2
1 1 1 2 Clutch or brake Dynamic Representation of Clutch or Brake

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TYPES OF CLUTCHES

1. Positive clutches
a) Jaw Clutch
The teeth of the mating sets of jaws are brought into engagement by sliding one or both members
axially. The teeth may be straight-sided or triangular, or they may incorporate some smooth curve to
facilitate engagement. Once the teeth are engaged, there is a positive transmission of torque. The jaw
clutch is normally engaged while the system is stopped or is running very slowly.

b) Toothed clutch

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2. Friction clutches
An axial clutch is one in which the mating frictional members are moved in a direction parallel to
the shaft. A typical clutch is illustrated in the figure below. It consist of a driving disc connected
to the drive shaft and a driven disc co9nnected to the driven shaft. A friction plate is attached to
one of the members. Actuating spring keeps both the members in contact and power/motion is
transmitted from one member to the other. When the power of motion is to be interrupted the
driven disc is moved axially creating a gap between the members as shown in the figure.

a) Single disk clutch (plate clutch)

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b) Multi-disk clutch

The operating force is


Z.. Number of contact surfaces.
P

pressure
coefficient of frication

c) Cone clutch

3. Hydraulic clutche

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2-4 BRAKES
TYPES OF BRAKES
A brake decelerates a system by transferring power from it. A clutch such as that illustrated (for the
most part) accelerates a system by transferring power to it. The two devices in rotary applications are
thus very similar as they both transmit torque whilst supporting a varying speed difference across them.

1. Shoe brake
Before examining a practical twin-shoe brake we must understand the behavior of a single shoe.
Various shoe configurations are illustrated. Each consists of a body whose motion is braked together
with a shoe which can swing freely about a fixed hinge H. A lining is attached to the shoe and contacts
the braked body. The actuation force P applied to the shoe gives rise to a normal pressure and
corresponding braking friction distributed over the area A of contact between lining and braked body.

2. Twin shoe brakes


Shoe behavior has been discussed at length. Two such shoes are combined into a complete practical
brake unit, two being used to minimize the unbalanced forces on the drum, shaft and bearings, and
because, as has been seen, linings become increasingly ineffective if they extend much beyond 90o to
110o. The shoes will be designated 1 and 2.
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The brake torque of the complete brake To is the sum of the torque contributions of the two shoes. The
shoes are operated by a single brake actuation source Po which may be a force in a brake rod or an
hydraulic pressure for example. This source is converted into the individual shoe actuations by some
actuating linkage, examples of which are shown at the beginning of the chapter. Since the two shoes
usually behave differently - one leading while the other trails - the actuating linkage is arranged to have
different transformation ratios between the source and the shoes so that the linings' peak pressures and
lives are not too different.

3. Band brake
A band brake consists of a flexible band faced with friction material bearing on the periphery of a drum
which may rotate in either direction.

The actuation force P is applied to the band's extremities through an actuation linkage such as the
cranked lever illustrated. Tension build-up in the band is identical to that in a stationary flat belt.

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These are external rigid shoe brakes - rigid because the shoes with attached linings are rigidly connected
to the pivoted posts; external because they lie outside the rotating drum. An actuation linkage
distributes the actuation force to the posts thereby causing them both to rotate towards the drum - the
linings thus contract around the drum and develop a friction braking torque.

4. Drum brake (inner shoe brake)


We now investigate the stability of road vehicles whilst braking during straight line motion, and consider
first a typical single non-driven wheel equipped with a drum brake of the type examined above. There
are three contacts between the wheel/brake drum/tyre system and its surrounds :
the ground, characterized by a tyre/ground adhesion coefficient k, and represented on the free body by
a normal force component N and a friction component F whose sense opposes vehicle translation vO
and whose magnitude cannot exceed the adhesion limit Fmax = kN when the wheel slides without
rotation on the ground, a condition known as wheel lock l the two brake shoes, which give rise to the
braking torque T and the force resultant R which are proportional to the brake actuation Po as discussed
above - provided the wheel is turning since friction force = m*normal reaction at the lining- drum

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contact only when there is relative motion between lining and drum l the wheel bearing at O, taken to
be essentially frictionless so that the sole effect here is the bearing reaction RO.

5. Disk brake

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Chapter 3
Belts Chains Gears
3 -1 Terms
Mechanical power may be transmitted between shafts , which have no common axis, by the following ways :

Belts

Chains

Gears

3-2 Belt Drive


1. characteristic
Belt drive has the folowing good characteristic
1. Connection of waidly as well as closely speed shafts is possible
2. There is only little noise in operation
3. There is chock absorption because of elasticity of the metrical
4. Safety against excessive load by belt slip
And bad characteristic is:
5. Because of slip an exact ratio of shaft speed cannot be maintained

2. material of belts

high cofficinet of firicition with metal


small resistance against bending
high tensile strength
remining expansion under load as small as possible

3. Types belt drive

Round belt

Flat belt

V- belt

Timing belt

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4. Round belt pully

5. Flat belt drive

a)
b)
c)
d)
e)
f)
g)

Open drive
Crossed drive
Half-crossed drive
Drive with giude rollers
Drive with stop pullys
Drive with fixed pulle and idler pulley
Drive with belt tensining pulley

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6. Flat belts pulleys


Generally made from cast iron, light casting metal or welded parts

Symetric hub

One piece

Asymetric hub

Holes in web

Welded pulley

Two pieces

7. V- belts drive
A v-belt drive has some imported advantage compered with flat belt
Extremely small slip
Higher transmittible power at equal maximum tension
Soft starting
Small angel of contact
Little space

8. V- belt pulleys

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9. Timing belt drive

10. Timing belt bulleys

11. Basic laws of belt dirive

Speed ratio

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3-3 Chain Drive


Chain = sequence of inner link and pin link articulated to form a flexible device for power transmission

1. characteristic
-

Pitch: distance between two consecutive pins

Roller diameter: dimension of the outside diameter of the chain rollers

Inside width: distance between the two opposite inner sides of the inner link plates

2. Types of power chain


-

roller chain
1.
2.
3.
4.
5.

pin link plate


roller link plate
pin
bushing
roller

silent chain
1. roller link plate
2. center plate
3. pin

3. Roller chains drive

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Two load conditions are generally considered for chain dimensioning:


-

Normal tension in the side plates

Shear on the pins

These verification may be useful to identify the load capacity of a chain installed on a mechanism

4. Silent chains drive

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3-4 Gear transmission


Gears are machine elements provided with teeth transmitting rotation and torque from one shaft
to the other one. Tramsmation of mation occures without slipping, by meshing of teeth.

1. Used of gear drive


To transimitte power from one rotating shaft ( driving ) to another ( driven) which may be
parallel, intersecting or skew under the following conditions:-

o
o
o
o
o

The distance between the axes of the connecting shafts is short.


The speed is low and the belt drive is not recommended .
The torque transmitted is high.
The speed or velocity of the connecting shafts is to be maintained constant.
To step up or step down the speed

2. Gear wheel made from :

o
o
o

Casting

By casting ( low speed )


By drop forged ( low speed )
By milling or grinding ( high speed )

Drop forged

Machined

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3. Basic type of gears :


gears may be classified as follows :-

Straight

Helical

Parellel

External

According to the form of tooth

Curved

Double helical

According to shaft position

Intersction

Skew

According to the position of gears in mech

Internal

Rack-super

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Solved problem
1. Drives
1-1 What are the possible types of drive can used in mechanical
system?
1-2 Calculate the power generated from water turbine, if waterfall
from 80 m height, with flow rate equal 500 m3/hr. if turbine
efficiency is about 80%.
( answer : 87200 watt/sec).
1-3 Calculate wind turbine power , if sweep area of blade equal
10m2, and wind velocity 30m/sec. ( answer: 46.125 watt/sec).
1-4 Calculate maximum tidal energy can be generated if seawater
level difference can reach to 20m and average flow rate
5000m3/sec.
( answer: 200000 watt/sec).

2. Coupling
2-1 What are the main differences between the following devices?
1- Coupling

2- clutch

3- brake

2-2 What are the main type of coupling?


2-3 Draw the possible position of shafts can be connected by
coupling.
2-4 Calculate the maximum torque can be transmitted by box
coupling if shaft diameter is 20mm , yield and shear stresses are
200, 400 MPs
( answer: 2x105 N-m).
2-5 Calculate the number of bolts used in muff coupling if maximum
torque can be transmitted is 2x105 N-m. and each bolt subject
to force equal 3x106 N, Dshaft =50mm.

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2-6 Calculate shearing pin diameter in safety coupling if number of


pins equal 10 and ultimate shearing stress 3.39x109 N and pitch
diameter 30mm. and maximum limit torque 10000 N-m .
( answer: 10 bolt).

3. Clutch
3-1 What are the main types of clutch?
3-2 Draw free hand sketch to show
A ) The different types of Jew clutch.
b) Friction clutch
c) Cone clutch

4. Break
4-1 Draw only the following types of brake
1- Shoe brake

2- Band brake

3- Disk brake

4- Draw brake

5. Belt
5-1
5-2
5-3
5-4

What are the good , bad characteristic of belt drive?


What are the types of belt drive?
Mention the belt material properties.
Draw a free hand sketch for

1. different arrangement of belt drive


5-5 What are the advantages of v belt over flat belt?
5-6 Draw a free hand sketch for the following belt drive pulleys
1. Round belt
2. Flat belt
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3. V- belt
4. Timing belt
Single belt drive:

Double belt drive:

Because

Where
(
(

)
)

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5-7 The transmission pulley of grinding wheel rotates with


n=360rpm, the cutting speed, or the grinding wheel has to be 25
m/s.
Find: 1) transmission ratio.

2) Diameter d4.

Solution:

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(Answer 1)

(Answer 2)

5-8 In double belt derive system shown below find I1, I2, I3,

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6. Chain
6-1 What are the main types of power chain

7. Gears
7-1 What are the main advantages of using gear drive?
7-2 Draw a free hand sketch to show types of gears.
1) Single gear drive:

2) Double gear drive:

7-3 The driven shaft of a gear drives rotates with speed


.
Find: 1- Transmission ratio

2-Number of teeth

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Solution:

Worm gear drive

Where: i= transmission ratio


n1= rpm of worm
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n2= rpm of worm gear


z1= number of teeth of worm (usually 1, 2 or 3)
z2= number of teeth of worm gear
7-4 The worm gear drive is provided with worm gear having z2=15
teeth. The single threaded worm rotates at 2880 rpm.

Find: 1. Transmission ratio

2. Rpm of worm gear

Solution: 1. i =

2.

Dimensions of spur gears:

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Circumference of circle

Where
t= m. x

Center distance between two gears c


c=
c=
7-5 The driving gear of spur gear drive rotates with n2=560 rpm.

Find 1. Transmission ratio


2. Rpm of the driven gear
3. Center distance between the two gears,
if the module m=3 mm
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Solution: 1.

i=

i= 1:0.75

n2 =

2.
3. c=

=
Good luck

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