DESIGN OF MACHINE ELEMENTS-I
UNIT I
Q.1 Explain various steps involved in the design of machine elements 4M
Q.2 Explain the term design synthesis 4M
Q3 Write a short note on Preferred size 4M
Q.4 What is preferred series? What are the advantages of it? 6M
Q.5 Write a short note on Eccentric loading 4M
Q.5 A ‘C’ frame subjected to a load of 10KN is shown in figure. It is made of grey cast iron with 6M
allowable nominal stress of 120N/mm2 Determine the dimensions of the cross section of the
frame
Q.6 A bracket is shown in figure is subjected to pull of 5KN acting at an angle of 450 to vertical. 6M
The bracket has a rectangular section whose depth is two times its thickness. If the permissible
tensile stress is 55N/mm2 , Determine the cross section of the bracket
Q.7 A beam of circular cross section of diameter 12mm has its center line curved to radius 60mm. 6M
Find the intensity of maximum stress in the beam when it is subjected to a moment of 45KN-
mm
Q.8 Design a cotter joint to transmit a load of 90KN in tension or compression. Assume the 10M
following stress for socket, spigot and cotter:
Allowable tensile stress = 90 N/mm2
Allowable crushing stress = 120 N/mm2
Allowable shear stress = 60 N/mm2
Q.9 A knuckle joint is subjected to an axial load of 100KN. Determine the diameter of knuckle pin 10M
considering the load to be uniformly distributed over the pin in the eye and uniformly varying
over the portion of pin in fork. Allowable tensile and compressive stress for pin is 600 N/mm2,
allowable shear stress for pin is 300 N/mm2and allowable bearing pressure for pin is 200
N/mm2. Take thickness of eye as 1.5d where d is pin diameter
Q.10 Design a knuckle joint for a tie rod of circular section for a maximum pull of 15 KN. The yield 10M
strength of material is 315 N/mm2 while allowable stress in shear is 100 N/mm2. Permissible
stresses are same in tension and compression. Take factor of safety as 2.
Q.11 A crank hook having circular cross section of 50mm diameter is made of plain carbon steel 10M
55C8 (syt = 400 N/mm2). The radius of curvature of censorial axis of the hook cross section is
80mm. If the required factor of safety is 5, Determine the load carrying capacity of the crank
hook.
Q.12 A foot lever has 1 m length between the center of the shaft and the point of application of 10M
force. The maximum force exerted by the foot is 800N. The lever has a rectangular cross
section with its depth as three times its thickness. The allowable tensile stress is 73 N/mm2,
while allowable shear stress sis 70 N/[Link]:
a. The diameter of the shaft;
b. The dimensions of the key; and
c. The dimensions of foot lever cross section at 60mm from the center of shaft.
Q.13 A bell crank lever is to design to raise a load of 5KN at the short arm end. The arm lengths are 10M
150mm and 500mm. The permissible stresses for lever and pin materials in shear and tension
are 60 N/mm2 and 90 N/mm2 respectively. The bearing pressure on the pin is to be limited to
12 N/mm2. Assume the lever cross section as t * 4t and fulcrum pin length as 1.25 times pin
diameter.
UNIT II
Q.1 Explain the steps for the design of muff coupling 6M
Q.2 Discuss different type of coupling and discuss design procedure for rigid flanged coupling. 6M
Q.3 What is A.S.M.E. code for shaft design? 4M
Q.4 An automobile gearbox uses a splined shaft to transmit power of 10KW at 1500rpm. The 10M
spline used is designated 6×28×34. The bearing pressure is limited to 5 N/mm2. Calculate the
length of splines in hub, based on bearing pressure criterion. Also determine forces required to
shift the gear if coefficient of friction is 0.05
Q.5 A steel spindle transmits 4KW power at 800r.p.m. The permissible angular deflection of the 6M
spindle is 0.250 per meter length. If the modulus of rigidity for the spindle material is 84GPa,
Determine:
a. The diameter of the spindle; and
b. The shear stress induced in the spindle
Q.6 Prove that the compressive stress induced in a square key due to transmitted torque is twice of 6M
shear stress.
Q.7 A steel shaft made of 40C8 is used to drive a machine. The pulleys X, Y and bearing A, B are 10M
located as shown in figure. Belt tensions are also shown in fig.1. Determine the diameter of the
shaft using A.S.M.E. code. Yield strength of short material is 330 MPa and ultimate tensile
strength is 600 MPa take Kb = 1.5 and Kt = 1.2. If rectangular key is made of the same
material, design the key.
Q.8 A transmission shaft supporting a spur gear B and pulley D as shown in fig.1. The shaft is 10M
mounted on two bearings A and C. The diameter of pulley and gear are 500 and 350 mm
respectively 20 KW power at 500 rpm is transmitted from the pulley to the gear: P1 and P2 are
the belt tensions in the tight and loose sides. While Pt and Pr are tangential and radial
components of the gear tooth force. Assume P1 = 3 P2 and Pr = Pt tan(20°). The gear and
pulley are keyed to the shaft. The material for the shaft is 50 C4 (Sut = 700N/mm2 and Syt =
460N/mm2) Determine the shaft diameter using ASME code if Kb=Kt=1.5
Q.9 What are the requirements of good shaft coupling 4M
Q.10 Design a flange coupling for steel shaft transmitting 20 KW power at 250rpm 10M
Maximum torque is 30% greater than full load torque. Material properties are as
follow:
1. Allowable shear stress for shaft & key = 40 N/mm2
2. Allowable shear stress for bolts = 30 40 N/mm2
3. Allowable crushing stress for shaft & key = 80 40 N/mm2
4. Allowable shear stress for flange = 14 40 N/mm2
5. Allowable compressive stress for bolts = 60 40 N/mm2
Take 4 bolts on P.C.D. -3d
Q.11 Design a C.I. flange coupling for a mild steel shaft transmitting 90KW at 250 r.p.m. The 10M
allowable shear stress for shaft material is 40 40 N/mm2. The allowable shear stress and
crushing stress for key and bolt material are 45 40 N/mm2 and 85 40 N/mm2 respectively. The
permissible shear stress for C.I. is 14 40 N/mm2. The key is having square cross section. The
numbers of bolts are 6 and the bolts are fitted in reamed and ground holes and are figure tight.
Q.12 The layout of an intermediate shaft of a gear box, supporting two spur gears B and C, is shown 10M
in figure. The shaft is mounted on two bearings A and D. The pitch circle diameter of gear B
and C are 900 mm and 600 mm respectively. The material of the shaft is steel FeE 580 (Sut =
770 and Syt = 580 N/mm2). The factors Kb and Kt are 1.5 and 2.0 respectively. Determine the
shaft diameter using the ASME code. Assume that the gears are connected to the shaft by
means of keys
UNIT III
Q.1 What are the methods of reducing stress concentration? Explain with neat sketch. 6M
Q.2 Define: 6M
a. Notch Sensitivity
b. Endurance Limit
c. Theoretical stress concentration factor
Q.3 Explain the term Notch Sensitivity and Endurance limit 4M
Q.4 What is Endurance strength of material? 4M
Q.5 Draw the following diagrams and write their equations 6M
a. Goodman diagram
b. Soderberg diagram
Q.6 Explain modified Goodman diagram for fluctuating axial or bending load 4M
Q.7 The mechanical element is subjected to a work cycle of complete reversed bending stresses 10M
as follows:
• 300 N//mm2 for 30% of time
• 275 N//mm2 for 25% of time
• 400 N//mm2 for 10% of time
• 325 N//mm2 for 25% of time
• No load for remaining time
The material has an ultimate tensile strength of 1200 N//mm2. Take surface finish factor as
0.8, size factor as 0.85 and reliability factor as 0.897. The operating temperature is 4000C for
which the temperature factor is 0.5. Assuming the fatigue stress factor at the most stressed
section as 0.7. Determine life of the component.
Q.8 A plate made of plane carbon steel 40C8 (Sut = 580 N/mm2), shown in figure is subjected to a 10M
completely reversed axial force of 40 KN. If the required factor of safety is 2, Determine the
plate thickness for infinite life. Use following data:
• Theoretical stress concentration factor = 2.27
• Notch sensitivity = 0.8
• Surface finish factor = 0.75
• Size factor = 0.85
• Load factor = 0.923
• Reliability factor = 0.897
Q.9 A steel bar of 5 mm diameter is subjected to a completely reversed bending stress of 25 10M
N/mm2. The ultimate tensile strength of steel is 600N/mm2. The surface finish factor and size
factor are.43 and .85 respectively. The reliability factor is 0.897. Assuming there is no stress
concentration. Determine the life of the bar
Q.10 The mechanical component is subjected to work cycle consisting of the following bending 10M
stresses:
• ± 350 N/mm2
• ± 500 N/mm2
• ± 400 N/mm2
The component is made of plain carbon steel 50C4 (Sut = 660 N/mm2). If the endurance limit
of component is 28 N/mm2. Determine its life.
Q.11 A spherical pressure vessel, with 500mm inner diameter, is welded from steel plates. The 10M
welded joints are sufficiently strong and do not weaken the vessel. The plates are made from
cold drawn steel 20C8 (Sut = 440N/mm2 and Syt = 242 N/mm2). The vessel is subjected to
internal pressure, which varies from to 6 N/mm2. The expected reliability is 50% and the
factor of safety is 3.5. The size factor and surface finish factor are 0.85 and 0.82 respectively.
The vessel is expected to withstand infinite number of stress cycles. Calculate the thickness
of the plates.
Q.12 A transmission shaft having an ultimate tensile strength of 600N/mm2 and yield Strength of 10M
380 N/mm2 is subjected to a fluctuating torque of 200 N-m anticlockwise and 800 N-m
clockwise. The factor of safety is 2 and the expected reliability is 50%. The surface factor is
0.8 and the size factor is 0.85. Assuming that there is no stress concentration, determine the
diameter of the shaft for infinite life.
Also determine the diameter of the shaft, if only the torque is to fluctuate between 10 N-m
anticlockwise and 800 N-m clockwise
Assume the distortion energy theory of failure