Design of Levers - Hand Lever, Foot Lever, Bell Crank Lever - MACHINE DESIGN Notes, Procedures, Problems and Vids

٢٠١٨/٥/٥ Design of Levers : Hand Lever, Foot Lever, Bell crank lever | MACHINE DESIGN Notes,Procedures,Problems and Vids
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Design of Levers : Hand Lever, Foot Lever,

crank lever
Submitted by admin on Mon, 06/05/2017 - 09:02
Design of levers
Key points to remember regarding design of levers :
the design of levers is all about finding the dimensions of the lever
could perform its function satisfactorily
A lever is force multiplier, depending upon the location of the load
from the fulcrum point.
Levers are classified on the basis of location of load, effort and fulc
point.
Levers are found in numerous machines and devices serving differ
purposes, mainly force transmission with multiplications.
Levers make our day to day life easier,they make ease in lifting, ea
cutting, ease in holding, ease in opening tight things. Hammer claw
barrows, pickup tonges,Scicors, bottle openers etc.are the example
day use of levers.
A lever is meant to make the work easy, so it actually reduces the e
required to do a work. The effort is always less than the load, other
lever or machine will be useless..
In mechanical engineering numerous applications have levers use
Mainly to transmit the force
http://machinedesign.top/content/design-levers-hand-lever-foot-lever-bell-crank-lever 1/22
Q.1. What is a mechanical Lever? What are its types?

Ans : A lever is defined as a mechanical device in the form of a rigid link which i
about a fulcrum to transfer or multiply the force.A lever is used for transmitting
one location to a different location alongwith change in direction or even chang
magnitude of the force. When the magnitude of the force is increases than that o
force, it is called the mechanical advantage of lever or simply LEVERAGE. A lev
rigid structure that oscillates around a fixed point called the fulcrum.
LEVERAGE example.{Source Wikipedia} : A 5 kg weight balances the 100 kg we

because the distance of 5 kg weight from the fulcrum is more and that of 100 kg
moment of both forces from the fulcrum is same.
Anatomy of the lever 1) Fulcrum : Point around which the lever Oscillates/rotat
2) Input Force : Force exerted on the lever
3)Output Force : Force exerted by the lever
Three Classes of Levers
There are three types or classes of levers which are based on the relative positio
effort point, the load point and the fulcrum.
They are as follows:
First Class - In this type the fulcrum between Input and output.This type of lev
applications like bell crank levers in railway signal mechanism,the rocker arm f
overhead valves of internal combustion engine, and levers of hand pump .
Second Class – In this type output between fulcrum and input.This type of lever
spring loaded safety valve mounted on the boilers.
Third Class – In this type input between fulcrum and output. This type of lever
recommended in engineering applications. A picking fork is best example of thi
lever.
Q.2. What are the stresses induced in the lever? How it is d
Ans : A lever acts like a cantilever from the pivot. A force acting at any end of th
to bend the lever and hence acts as abending force. Hence the prime effect of a f
end of the lever is to create a BENDING STRESS on the lever cross section. It is
us that any bending stress is always of either tensile or compressive nature. The
generally made up of a convenient cross section like rectangle, square, I section
care is taken to see that the section modlus of the cross section is larg
A lever is designed using the bending equation,
Where M= Bending moment { Either ) Whichever is larger
I= Moment of inertia
Allowable bending stress
y = Distance of extreme fibre from neutral axis .( for most sections it is hal
of section)
Q.3. What is rocket arm? Where it is used?

Ans : In four stroke IC engines, there are inlet and outlet valves for the purpose
the air( or charge) in the cylinder and pushing the exhaust gases after the exhau
into the surrounding. This vale is opened and closed by a rocker arm, through c
and push rod as shown below.
Q.4. Enlist Various applications of lever in Mechanical

engineering? Illustrate with diagrams wherever necessary
Ans : Levers are used for variety of applications in mechanical engineering for t
of transmitting or magnifying the force.
Following are the examples which show their use in mechanical engineering.
1) Application of lever in Boilers
2) Applicaiton of lever in I C Engines.
3) Application of lever (Foot lever and hand lever)
4) In governors bell crank levers are used.
5) Levers in Robotics : Hundreds of levers are used in robot and robotic machin
(IMAGE BY : Siaopan ,
CC BY-SA 4.0 Source : Wikipedia)
Principle of design of levers

Levers are found everywhere in the machines and automobiles, out o
hand lever and foot levers are those which are manually operated fo
of some action like shifting gear or applying brake etc. The basic prin
behind the design of hand and foot lever is that it shoulf withstand th
and should not fail in bending. To avoid the bending or bending failu
hand or foot lever it is necessary that the section of the lever should
sufficient moment of inertia to resist the bending. For this purpose t
and foot levers are made of rectangular or I sections with vertical sid
than the horizontal side. The dimensions of crosssection are determ
basis of flexural formula, which is the relation between bending mom
moment of inertia and the bending stress induced in the section. The
bending stress should be less than the allowable bending stress for th
material. In addition to the lever cross section there is a boss which i
be designed based on the torsional shear stress induced in it, also th
which is rotated by lever is also designed first on the basis of the tors
shear stress induced.
Steps in Design of Levers
Force Analysis
A lever is a bar which can rotate about a fixed axis called fu

axis, which is actually pin on which the lever is mounted. T
purpose of a lever is to lift a load or apply a force, through
aplied at another point. The shape of the lever is convenien
choosen with respect to the requirement and applications,
include rectangular, eliptical or I section. The principle of
operation of lever is based on the law of moments about a
Taking moment about the fulcrum we can find the effort an

acting on the lever, this give us F(Load) or P(Effort),
The resultant force acting at the fulcrum is given by,
If the lever is bell crank lever tha angle theta is 900 and as
of 900 is zero the formula reduces to first two terms only.
Design of Fulcrum Pin :
The fulcrum pin is subjected to the resultant reaction R, as

calculated above. The pin is designed on the basis of allowa
bearing pressure and shear stress induced.
Generally the length of pin is assumed to be 1.25 times the

of pin for ease of calcualtion.
......................This equation i
determine the diamter and length of the pin.
Then the actual shear stress induced in the pin due to resu
force is found using formula considering the double shear
pin,
This induced stress should be below the allowable shear st
Design of lever crosssection :
After finding the forces acting on the lever, the next step is
design the crosssection of the lever. The crosssection of th
subjected to bending moment,
The maximum bending moment is at the farthest distance

force and it is given by,
The crosssection of the lever is generally given as rectangu

its depth to width ratio as 2 to 4, For rectangular section
then using the flexural formula the dimensions of the cros

are determined,
For the handlever and foot lever there are some additional
which are discussed in problems
Numerical Problems :
A) Problems on Bell Crank Lever
1) Design a bell crank lever i to raise a load of 5 KN at the s

arm end by applying proper effort. The arm lengths are 150
500mm. The permissible stresses for lever and pin materi
shear and tension are 60N/mm2 and 90N/mm2 respectivel
bearing pressure on the pin is to be limited to 12 N/mm 2 .
the lever cross section as rectangular with b=4t and fulcru
length as 1.25 times pin diameter.
2) Design a right angled bell-crank lever to raise a load of 5

N, at the short arm end. The lengths of short and long arm
mm and 450 mm respectively. The material used for the le
the
pins is steel 30 C 8 ( σ yt = 400 MPa) with the factor of safe
The permissible bearing pressure on the pin should be lim
to 10 MPa. The rectangular cross-section of lever has ratio
to the thickness is 3 : 1 and take the length to diameter rati
falcrum pin is 1.25 : 1. Calculate,
i) The dimensions of fulcrum pin
ii) The shear stress induced in the pin
iii) The width and thickness of lever
The arm of the bending moment on the lever extends up to
of the fulcrum.
3) A right angled bell crank lever is used in a mechanism h

smaller arm 250 mm and longer arm 500 mm respectively
fulcrum. It is required to lift a load of 5 kN at the end of lon
The lever and pins are made up of steel having ultimate ten
strength of 250 n/mm2 and factor of safety 4. Using allowa
bearing pressure 10 N/mm2, find the dimensions of lever a
Take crosssection of lever as rectangular and width to thic

ratio as 4. Take length of pin as 1.25 times its diameter.
4) It is required to design a bell crank lever which is subjec

force of 7500 N at the short arm end, which is 100 mm from
fulcrum whereas the longer arm is 500 mm long. The lever
pins are made up of the material which has syt=300 N/mm
factor of safety is 4. the permissible bearing pressure is 12
The crosssection of lever is rectangular and the ratio of wid
thickness is 4:1. The ratio of lenth to diameter for the fulcr
1.25:1. Calculate,
1) the diameter and the length of the fulcrum pin,
2) Shear stress induced in the pin,
3) The dimensions of the crossection of lever ( width and th
Assume that bending moment of the lever is extended up t

of the fulcrum.
B) Safety valve lever for boiler
1) A lever loaded safety valve used in boiler is used to blow

pressure value of 1.5 MPa gauge paressure. The diamter of
opening is 50 mm. The lever length from fulcrum to dead w
1000 mm whereas that of between fulcrum and pin connec
valve spindle is 100 mm. Using permissible bearing pressu
MPa,allowable Bending stress as 80 Mpa , allowable shear
40 Mpa. Design the lever using the width to thickness ratio
Design of Hand lever and foot lever

As the names suggest Hand lever is operated by hand and the foot lev
the basic design procedure of both the levers remains the same with
difference that more froce is applied on the foot lever, so its crosssec
dimensions are naturally bigger than that of a hand lever. Second po
there is handle in hand lever and pedal in foot lever.
As far the parts which we have to design are
1) Shaft : Which transmits the motion/force from hand/foot lever to

machine part, it is subjected to Torque.
2) Boss : Which holds the shaft and is coupled to shaft with a Key, it a
hollow shaft and subjected to torque.
3) Key : The function of key is to couple the shaft and the boss. It is su
shear as well as crushing stress
4) Lever crosssection : The lever crossection is assumed to be rectan

calculation purpose. It is subjected to bending stress.
Diagram and Notations
Step 1 :Design Of shaft and Boss :( )
1) Diameter of shaft d {subjected to torque only}

Torque Acting on Shaft
T= P L
Diameter of Shaft obtained on basis of shear stress
Find diameter of shaft d using this equation

2) Diameter of shaft at centre of bearing d1 {Subjected to t

and Bending moment}
Bending Moment acting on shaft
M=P l
Equivalent torque acting on shaft
Diameter of Shaft at centre of bearing on the basis of shear strength
Find diameter of shaft d1 using this equation
3) Dimensions of Boss (Which holds the shaft)
Step 2 : Design Of Key :

Using a square Key
, ,
Shear Failure of key
Find lk using eqn. above
Step 3 : Design Of cross-section of lever ( B,t )
Using bending equation ,
Using this equation find B and t of lever.{Assume B=3t or any other relation giv
problem}
The lever is subjected to bending moment,
M=
Moment of inertia
Allowable stress for lever material
Distance of extreme fiber form N-A
Steps in Short
Part Failure Equation
T= P L
Shaft Torsional shear stress
{d,d1}
M=P l
Torsional shear stress
Boss
Emperical relations
{d2,l2}
Key Emperical relation {sq key}
{Wk,tk,lk}
Shear Failure of Key
M=
Lever Cross section
{t,B}
B) Problems on Hand lever and foot Lever
1) Design a foot lever, which is 1000 mm from the centre o

the point of application of 800 N load. Find: Dimensions o
rectangular arm of the foot lever at 60 mm from the centre
assuming width of the arm as 3 times thickness. The allow
tensile stress may be taken as 73 N/mm 2 .
2) The effective length of hand lever is 1 meter. The effectiv

overhang from the nearest bearing is 150mm. The lever an
are made of alloy steel for which tensile yield strength is 46
the maximum force exented at the handle is 300N, design
and the shaft with a safety with a safety factor of 4.
Ans: 1) d = 30mm, 2) = 48mm, 3) = 46.5mm 4) = 30mm, 5)

12mm, h = 36mm 3.
3)A hand lever for a brake is 0.8 m long from the centre of
of the spindle to the point of application of the pull of 300
effective overhang from the nearest bearing is 100 mm. If t
permissible stress in tension, shear and crushing is not to
66 MPa, design the spindle, key and lever. Assume the arm
lever to be rectangular having width twice of its thickness.
Links to other Topics in Machine design I
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Design Of Bolted and Welded Joints
Design of Shafts: Theory and Numerical Problems
Couplings : Design Procedure and Numerical problems
Design Of SPRINGS : Questions and Numerical problems
Power Screw Design
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Design of Levers - Hand Lever, Foot Lever, Bell Crank Lever - MACHINE DESIGN Notes, Procedures, Problems and Vids

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٢٠١٨/٥/٥ Design of Levers : Hand Lever, Foot Lever, Bell crank lever | MACHINE DESIGN Notes,Procedures,Problems and Vids

MACHINE DESIGN Notes,Procedures,Problems and

Design of Levers : Hand Lever, Foot Lever,

Key points to remember regarding design of levers :

Q.1. What is a mechanical Lever? What are its types?

LEVERAGE example.{Source Wikipedia} : A 5 kg weight balances the 100 kg we

2) Input Force : Force exerted on the lever

3)Output Force : Force exerted by the lever

Three Classes of Levers

They are as follows:

Q.2. What are the stresses induced in the lever? How it is d

A lever is designed using the bending equation,

Where M= Bending moment { Either ) Whichever is larger

Allowable bending stress

Q.3. What is rocket arm? Where it is used?

Q.4. Enlist Various applications of lever in Mechanical

1) Application of lever in Boilers

2) Applicaiton of lever in I C Engines.

3) Application of lever (Foot lever and hand lever)

4) In governors bell crank levers are used.

CC BY-SA 4.0 Source : Wikipedia)

Principle of design of levers

Steps in Design of Levers

A lever is a bar which can rotate about a fixed axis called fu

Taking moment about the fulcrum we can find the effort an

The resultant force acting at the fulcrum is given by,

Design of Fulcrum Pin :

The fulcrum pin is subjected to the resultant reaction R, as

Generally the length of pin is assumed to be 1.25 times the

This induced stress should be below the allowable shear st

Design of lever crosssection :

The maximum bending moment is at the farthest distance

The crosssection of the lever is generally given as rectangu

then using the flexural formula the dimensions of the cros

A) Problems on Bell Crank Lever

1) Design a bell crank lever i to raise a load of 5 KN at the s

2) Design a right angled bell-crank lever to raise a load of 5

3) A right angled bell crank lever is used in a mechanism h

Take crosssection of lever as rectangular and width to thic

4) It is required to design a bell crank lever which is subjec

1) the diameter and the length of the fulcrum pin,

2) Shear stress induced in the pin,

3) The dimensions of the crossection of lever ( width and th

Assume that bending moment of the lever is extended up t

B) Safety valve lever for boiler

1) A lever loaded safety valve used in boiler is used to blow

Design of Hand lever and foot lever

As far the parts which we have to design are

1) Shaft : Which transmits the motion/force from hand/foot lever to

4) Lever crosssection : The lever crossection is assumed to be rectan

Diagram and Notations

Step 1 :Design Of shaft and Boss :( )

1) Diameter of shaft d {subjected to torque only}

Diameter of Shaft obtained on basis of shear stress

Find diameter of shaft d using this equation

2) Diameter of shaft at centre of bearing d1 {Subjected to t

Equivalent torque acting on shaft

Diameter of Shaft at centre of bearing on the basis of shear strength

Find diameter of shaft d1 using this equation

3) Dimensions of Boss (Which holds the shaft)

Step 2 : Design Of Key :

Shear Failure of key

Find lk using eqn. above