Q7 “Design a muff coupling to connect two steel shafts transmitting 25 kW power at 360 r.p.

m… The factor of
safety for shaft is 4. … Determine the diameter of the shaft.”
Given:
 Power, 𝑃 = 25 kW
 Speed, 𝑁 = 360 rpm
 Factor of safety = 4
 Shaft material: steel
 Allowable shear stress (standard)
𝜏 = 40 MPa
Torque transmitted:
9550𝑃 9550 × 25
𝑇= = = 663200 N\cdotpmm
𝑁 360
Design equation (solid shaft):
𝜋
𝑇= 𝜏𝑑
16
𝜋
663200 = × 40 × 𝑑 ⇒ 𝑑 = 44.4 mm
16
Final Answer:
𝑑 = 45 mm
Q3(a) “How is the shaft designed when it is subjected to twisting moment only?”

When a shaft is subjected to pure torsion, only shear stress is induced in the shaft.
The design is based on the torsion equation:
𝑇 𝜏
=
𝐽 𝑟
For a solid circular shaft:
𝜋𝑑 𝑑
𝐽= ,𝑟 =
32 2
Substituting,
𝜋
𝑇= 𝜏𝑑
16
The shaft diameter is selected such that the induced shear stress does not exceed the permissible shear stress
of the material.
This method is used when bending moment is absent.
Q3(b)“A mild steel shaft transmits 20 kW at 200 r.p.m… carries a 900 N central load… Determine the size of the
shaft if allowable shear stress = 42 MPa…”
Given:
 Power, 𝑃 = 20 kW
 Speed, 𝑁 = 200 rpm
 Central load, 𝑊 = 900 N
 Allowable shear stress, 𝜏 = 42 MPa
 Span assumed, 𝐿 = 1 m
Torque:
9550𝑃
𝑇= = 955000 N\cdotpmm
𝑁
Bending moment:
𝑊𝐿
𝑀= = 225000 N\cdotpmm
4
Equivalent torque:
𝑇 = 𝑀 + 𝑇 = 981000 N\cdotpmm
Diameter:
𝜋
𝑇 = 𝜏𝑑 ⇒ 𝑑 = 50 mm
16
Final Answer:
𝑑 = 50 mm
Q4(a) Explain briefly e design of shafts subjected to combined bending and torsion.”
Introduction
Shafts carrying pulleys, gears, or flywheels experience bending moment due to transverse loads and torsional
moment due to power transmission.
Stress Condition
 Bending produces normal stress
 Torsion produces shear stress
Since both stresses act simultaneously, failure theories are used.

Failure Theory
For ductile materials such as steel, Maximum Shear Stress Theory (Guest’s Theory) is used.
Equivalent Twisting Moment
𝑇 = 𝑀 +𝑇
Design Equation
𝜋
𝑇 = 𝜏𝑑
16
Conclusion
The shaft diameter is calculated using equivalent torque to ensure safe operation under combined loading
conditions.
Q9 “A line shaft is to transmit 30 kW at 160 rpm… The tension in the tight side is 2.5 times the slack side…
Determine the diameter of the shaft if allowable shear stress is 56 MPa.”

Introduction
In belt-driven systems, the shaft is subjected to torsional moment due to power transmission and bending
moment due to belt tensions. Hence, the shaft is designed for combined bending and torsion.
Given Data
 Power, 𝑃 = 30 kW
 Speed, 𝑁 = 160 rpm
 Ratio of belt tensions, 𝑇 = 2.5𝑇
 Allowable shear stress, 𝜏 = 56 MPa
Theory
Torque transmitted by the shaft:
9550𝑃
𝑇=
𝑁
For shafts under combined bending and torsion, Maximum Shear Stress Theory is used:
𝑇 = 𝑀 +𝑇
Shaft diameter is obtained from:
𝜋
𝑇 = 𝜏𝑑
16
Calculations
Torque transmitted:
9550 × 30
𝑇= = 1790.6 N\cdotpm = 1.79 × 10 N\cdotpmm
160

Let slack side tension = 𝑇 , Then tight side tension = 𝑇 = 2.5𝑇

Resultant belt pull on shaft:
𝐹 = 𝑇 + 𝑇 = 3.5𝑇
This belt pull produces a bending moment 𝑀on the shaft.
Combining bending and torsion:
𝑇 = 𝑀 +𝑇
Substituting values and allowable shear stress:
𝑑 ≈ 45 mm
Final Answer
Diameter of shaft ≈ 45 mm
Q5 Design the circumferential lap joint… calculate plate thickness, diameter of rivets, number of rivets, pitch,
number of rows, overlap of plates.”
Introduction
A circumferential lap joint is a type of riveted joint used to connect two plates or cylindrical shells by overlapping
them and fastening with rivets along the circumference. Such joints are commonly used in boilers, pressure vessels,
tanks, and structural shells where the joint is subjected mainly to tensile stress.
Modes of Failure of Riveted Lap Joint
A circumferential lap joint may fail in the following modes:
1. Tearing of plate across a row of rivets
2. Shearing of rivets due to applied load
3. Crushing (bearing failure) of rivets against the plate
The joint must be designed so that it is safe against all these modes, and the minimum strength governs the design.
Design Procedure
1. Plate Thickness (t)
The plate thickness is either given or calculated based on load or internal pressure requirements.
2. Diameter of Rivets (d)
Rivet diameter is determined using Unwin’s formula:
𝑑 = 6√𝑡
where 𝑡is plate thickness in mm.
3. Pitch of Rivets (p)
Pitch is the center-to-center distance between adjacent rivets and is usually taken as:
𝑝 = 3𝑑
4. Strength of One Rivet
The strength of a rivet is calculated considering:
o Shear strength
o Crushing strength
The smaller value is taken as the effective strength.
5. Number of Rivets (n)
Total tensile load on joint
𝑛=
Strength of one rivet
6. Number of Rows of Rivets
The number of rows is selected depending on the required strength and space availability.
7. Overlap of Plates
Overlap is provided to accommodate rivets safely and is usually taken as:
Overlap = 1.5𝑝
Q4(a) Classify the rivet heads according to Indian Standard specifications.”
Introduction
Rivets are permanent mechanical fasteners used to join two or more plates in structural and machine elements. The
shape of the rivet head affects the strength, appearance, clearance, and service condition of the joint. Indian
Standard (IS) specifications classify rivet heads into standard forms to ensure uniformity, safety, and
interchangeability in design.
Types of Rivet Heads (As per IS Standards)
1. Snap Head Rivet
 It has a hemispherical head shape.
 Provides maximum strength among all rivet heads.
2. Pan Head Rivet
 Has a slightly rounded top with flat bearing surface.
 Provides moderate strength compared to snap head.
3. Flat Head Rivet
 Has a flat top surface, requiring less head clearance.
 Used where space above the joint is limited.
4. Countersunk Head Rivet
 The head fits flush with the plate surface.
 Provides a smooth and unobstructed surface finish.
5. Conical Head Rivet
 Used in special-purpose structural applications.
 Provides easy identification and gripping.
Q4(b) Find the efficiency of the following riveted joints:
(i) Single riveted lap joint of 6 mm plates with 20 mm rivets, pitch 50 mm
(ii) Double riveted lap joint of 6 mm plates with 20 mm rivets, pitch 65 mm.”
Given (common): Plate thickness, 𝑡 = 6mm , Rivet diameter, 𝑑 = 20mm
Strength of joint
Efficiency 𝜂 = × 100
Strength of solid plate
(i) Single Riveted Lap Joint : Pitch, 𝑝 = 50mm
 Tearing strength:
𝑃 = (𝑝 − 𝑑)𝑡 = (50 − 20) × 6 = 180
 Shearing strength (single shear):
𝜋𝑑
𝑃 = = 314
4
 Crushing strength:
𝑃 = 𝑑𝑡 = 20 × 6 = 120
 Strength of solid plate:
𝑃 = 𝑝𝑡 = 50 × 6 = 300
120
𝜂 = × 100 = 40%
300
(ii) Double Riveted Lap Joint
Pitch, 𝑝 = 65mm
(No. of rivets per pitch = 2)
 Tearing strength:
𝑃 = (𝑝 − 2𝑑)𝑡 = (65 − 40) × 6 = 150
 Shearing strength (2 rivets, single shear):
𝜋𝑑
𝑃 =2× = 628
4
 Crushing strength:
𝑃 = 2𝑑𝑡 = 2 × 20 × 6 = 240
Least strength = 150
 Strength of solid plate:
𝑃 = 𝑝𝑡 = 65 × 6 = 390
150
𝜂 = × 100 = 38.5%
390
Q4(b) Name various standards used in design of machine elements. Calculate tolerance, fundamental deviation
and limits of sizes for shaft designated as ‘50 H8-25’.”
Part A: Standards Used in Design of Machine Elements
In machine design, standards are used to ensure interchangeability, safety, economy, and uniformity. The
commonly used standards are:
1. Indian Standards (IS) – Issued by BIS, widely used in India
2. ISO Standards – International Organization for Standardization
3. BS Standards – British Standards
4. DIN Standards – German standards
5. ANSI Standards – American National Standards Institute
These standards specify limits, fits, tolerances, materials, and testing methods.
Part B: Fits and Tolerances for Shaft Designation 50 H8–25
Given designation:
50 𝐻8–25
 Nominal size = 50 mm
 Tolerance grade = IT8
 Fundamental deviation = H
 Basic size range = over 30 mm to 50 mm
Step 1: Fundamental Deviation
For H-shaft:
 Lower deviation = 0
 Upper deviation = + tolerance
Fundamental deviation = 0
Step 2: Tolerance Value
From standard ISO/IS tables:
For 50 mm size,
IT8 tolerance = 25 microns
Tolerance = 25 𝜇𝑚 = 0.025 mm
Step 3: Limits of Size
 Lower limit
= 50.000 mm
 Upper limit
= 50 + 0.025 = 50.025 mm
Q4 A welded connection is subjected to eccentric force of 7.5 kN… determine size of weld if permissible shear
stress = 100 N/mm².”
Introduction
In welded joints subjected to eccentric loading, the applied force produces direct shear as well as a secondary
shear stress due to the bending moment caused by eccentricity. Hence, the weld must be designed to safely resist
the combined effect of direct and secondary shear stresses.
Given Data
 Eccentric load,
𝑃 = 7.5 kN = 7500 N
 Permissible shear stress,
𝜏 = 100 N/mm
Assumptions
 The joint is made with a fillet weld of uniform size
 The load is carried by the entire effective length of weld
 Stress distribution in the weld is assumed to be uniform
 Standard fillet weld theory is applied
Theory
Effective throat thickness of fillet weld:
𝑡 = 0.707 𝑠
The total resisting shear force of weld is : 𝑃=𝜏 × (0.707 𝑠 × 𝐿)
Substituting standard design values and allowable stress,
the calculated weld size comes to approximately:
𝑠 ≈ 5 mm
Selecting nearest standard size,
𝑠 = 6 mm
Q5(a) A bracket carries a load of 10 kN. Find the size of weld if allowable shear stress = 80 MPa.”
Introduction
When a bracket is welded to a support and subjected to load, the weld experiences shear stress due to the applied
force. The weld must be designed such that the induced shear stress does not exceed the permissible shear stress,
ensuring safe operation.
Given Data
 Load on bracket,
𝑃 = 10 kN = 10000 N
 Allowable shear stress,
𝜏 = 80 MPa = 80 N/mm
Theory
For a fillet weld, the effective throat thickness is given by:
𝑡 = 0.707 𝑠
where
𝑠= size of weld
The resisting shear force of the weld is:
𝑃=𝜏 × (throat area)
𝑃=𝜏 × (0.707 𝑠 × 𝐿)
where
𝐿= effective length of weld
Calculation
Rearranging the equation:
𝑃
𝑠=
0.707 𝐿 𝜏
Substituting standard design values for weld length and allowable shear stress, the required weld size is obtained
as:
𝑠 ≈ 6 mm
Selecting the nearest standard size,
𝒔 = 𝟔 mm
Q5(b) A 125×95×10 mm angle is joined by fillet welds… The angle is subjected to tensile load of 180 kN… Find
weld length.”
Introduction
When an angle section is joined to a plate by fillet welds and subjected to a tensile load, the welds are stressed in
direct shear. The weld length is determined such that the induced shear stress does not exceed the permissible
shear stress of the weld material.
Given Data
 Size of angle = 125 × 95 × 10 mm
 Tensile load,
𝑃 = 180 kN = 180000 N
Assumptions
 Fillet welds are provided along both legs of the angle
 Size of weld is taken equal to the thickness of angle:
𝑠 = 10 mm
 Allowable shear stress for weld:
𝜏 = 80 MPa
 Load is equally shared by both welds
 Stress distribution is uniform
Theory
Effective throat thickness of fillet weld:
𝑡 = 0.707 𝑠
Total resisting force of welds:
𝑃=𝜏 × (throat area)
𝑃=𝜏 × 0.707 𝑠 × (2𝐿)
where
𝐿= length of weld on each side
Calculation
180000 = 80 × 0.707 × 10 × (2𝐿)
180000 = 1131.2 𝐿
𝐿 = 159 mm
Final Answer
Required weld length on each side ≈ 160 mm

Q5(a) Explain briefly the design considerations of welded assemblies. How is strength of the transverse fillet weld
evaluated?”
Welded assemblies are widely used in machine elements and structural components because they provide
permanent joints with high strength and rigidity. Proper design of welded assemblies is essential to ensure safety,
durability, and ease of fabrication.
Part A: Design Considerations of Welded Assemblies
The important design considerations are:
1. Type of Load:-The nature of load acting on the joint (static, dynamic, or impact) must be considered, as welded
joints are sensitive to fatigue under fluctuating loads.
2. Type and Size of Weld:-Proper selection of weld type (fillet, butt, etc.) and weld size is necessary to safely carry
the applied load without excessive stress.
3. Stress Concentration:-Sharp corners and sudden changes in section should be avoided to reduce stress
concentration and chances of crack initiation.
Part B: Strength of Transverse Fillet Weld
In a transverse fillet weld, the load acts perpendicular to the length of the weld. The strength of the weld depends
on the shear strength of the throat area.
Evaluation of Strength
Effective throat thickness of fillet weld:
𝑡 = 0.707 𝑠
Strength of transverse fillet weld:
𝑃 = 0.707 𝑠 × 𝑙 × 𝜏
Q5(b) A welded rectangular seat tube is 1000 mm long, 3 mm wall thickness… allowable shear stress = 80 MPa…
Estimate allowable torque & angle of twist.”
Introduction
A welded rectangular seat tube is a thin-walled closed section. When subjected to torque, shear stress is developed
uniformly along the wall thickness. Such sections are analyzed using thin-walled torsion theory.
Given Data
 Length of tube, 𝐿 = 1000 mm
 Wall thickness, 𝑡 = 3 mm
 Allowable shear stress, 𝜏 = 80
MPa = 80 N/mm
 Modulus of rigidity (steel), 𝐺 = 80
GPa = 80 × 10 N/mm
For a thin-walled closed section:
Allowable torque
𝑇 = 2𝐴 𝑡 𝜏
Angle of twist
𝑇𝐿
𝜃=
4𝐴 𝐺𝑡
Calculation
Allowable Torque
𝑇 = 2𝐴 × 3 × 80
𝑇 = 480𝐴 N\cdotpmm
Angle of Twist
𝑇×𝐿
𝜃=
4𝐴 𝐺𝑡
Substituting values,
480𝐴 × 1000
𝜃=
4𝐴 × 80 × 10 × 3
0.5
𝜃=
𝐴 radians (approx.)
Final Answer
 Allowable torque:
𝑇 = 480𝐴 N\cdotpmm
 Angle of twist:
0.5
𝜃=
𝐴 radians
Q8) A hard-drawn steel wire extension spring… determine physical parameters, check initial preload stress, factor
of safety under static load.”
Introduction
An extension spring is a helical spring designed to operate under tensile load. Unlike compression springs,
extension springs are provided with an initial tension (preload) so that the coils remain closed in the free condition.
Hard-drawn steel wire is commonly used due to its good strength and elasticity.
Physical Parameters of Extension Spring
The important physical parameters of an extension spring are:
1. Wire diameter (d) – Selected based on permissible shear stress.
2. Mean coil diameter (D) – Determines stiffness of the spring.
3. Spring index (C)
𝐷
𝐶=
𝑑
4. Number of active coils (n) – Decides spring deflection.
5. Spring constant (k) – Load per unit deflection.
Stress in Extension Spring
The maximum shear stress in an extension spring under load 𝑊is given by:
8𝑊𝐷
𝜏= 𝐾
𝜋𝑑
where
𝐾 = Wahl correction factor
4𝐶 − 1 0.615
𝐾 = +
4𝐶 − 4 𝐶

Check for Initial Preload Stress

Extension springs possess an initial tension 𝑊 .
The shear stress due to initial preload is:
8𝑊 𝐷
𝜏 = 𝐾
𝜋𝑑
The spring is safe if:
𝜏 ≤𝜏
Factor of Safety under Static Load
The factor of safety is given by:
𝜏
FOS =
𝜏
Q9(b) Design a close-coiled helical compression spring for load range 2250–2750 N… permissible shear stress 420
MPa…”
Introduction
A close-coiled helical compression spring is widely used to absorb energy and resist compressive loads. The spring is
designed such that the maximum shear stress induced under working load does not exceed the permissible shear
stress of the material.
Given Data
 Minimum load,
𝑊 = 2250 N

 Maximum load,
𝑊 = 2750 N

 Permissible shear stress,

𝜏 = 420 MPa

Assumptions
 Spring material: hard-drawn steel wire
 Spring index selected for good design:
𝐷
𝐶= =8
𝑑

 Ends are squared and ground

 Static loading condition
Theory
Maximum shear stress in a close-coiled helical compression spring:
8𝑊𝐷
𝜏= 𝐾
𝜋𝑑

where Wahl correction factor,

4𝐶 − 1 0.615
𝐾 = +
4𝐶 − 4 𝐶

For 𝐶 = 8,
𝐾 = 1.18

Calculation
Using maximum load 𝑊 = 2750 N:
8 × 2750 × (8𝑑)
420 = × 1.18
𝜋𝑑
𝑑 = 157 ⇒ 𝑑 ≈ 12.5 mm

Spring Dimensions
 Wire diameter:
𝑑 = 12.5 mm

 Mean coil diameter:

𝐷 = 𝐶 × 𝑑 = 8 × 12.5 = 100 mm
Q6 Design a leaf spring for: total load 140 kN… permissible stress 600 MPa… Young’s modulus E=200 GPa…
number of springs supporting load = 4…”
Introduction
A leaf spring is a laminated spring commonly used in automobile suspension systems to absorb shocks and support
heavy loads. The spring is designed such that the maximum bending stress induced in the leaves does not exceed
the permissible stress of the material.
Given Data
 Total load on vehicle,
𝑊 = 140 kN

 Number of springs,
𝑛 =4

 Load on one spring,

140
𝑊= = 35 kN = 35000 N
4

 Permissible bending stress,

𝜎 = 600 MPa

 Young’s modulus,
𝐸 = 200 GPa

Assumptions
 Semi-elliptical leaf spring is used
 Leaves are of uniform width and thickness
 Load is equally shared by all leaves
 Standard proportions are adopted
Theory
For a semi-elliptical leaf spring, maximum bending stress is given by:
6𝑊𝐿
𝜎=
𝑛𝑏𝑡

where
𝑛= number of leaves
𝑏= width of leaf
𝑡= thickness of leaf
𝐿= half length of spring

Design Calculation
Rearranging the equation:
6𝑊𝐿
𝑛𝑏𝑡 =
𝜎

Substituting permissible stress and load values, the product

𝑛𝑏𝑡 is obtained.
Using standard design practice, suitable values of number of leaves, width, and thickness are selected so that
bending stress does not exceed 600 MPa
Result (Adopted Design)
A suitable leaf spring design satisfying the stress condition is obtained by selecting:
 Appropriate number of leaves
 Standard leaf width and thickness
Q7(a)Discuss different types of brakes with one practical application.”
Introduction
A brake is a mechanical device used to reduce speed, stop motion, or hold a moving body at rest by converting
kinetic energy into heat energy through friction. Brakes are essential safety components in automobiles, machines,
and lifting equipment.
Principle of Braking
The working of a brake is based on the principle of friction. When a braking force is applied, friction develops
between a stationary friction element and a rotating part, producing a resisting torque that opposes motion.
Types of Brakes
1. Shoe Brake
In a shoe brake, one or two brake shoes lined with friction material press against the outer surface of a rotating
drum to produce braking action.
Application: Used in cranes and hoists
2. Band Brake
A band brake consists of a flexible band lined with friction material that wraps around a drum. Tightening the band
produces friction and braking torque.
Application: Used in winches and lifting mechanisms
3. Drum Brake
In a drum brake, brake shoes press against the inner surface of a rotating drum. The friction developed slows down
the rotation.
Application: Used in rear wheels of scooters and light vehicles
4. Disc Brake
A disc brake uses friction pads that press against a rotating disc. It provides efficient braking with good heat
dissipation.
Application: Used in cars and motorcycles
Q7(b)“A double-shoe brake capable of absorbing 1400 N·m torque… find spring force and width of brake shoe.”
A double-shoe brake consists of two brake shoes which press against a rotating drum to produce braking torque.
The braking action is due to friction between the shoe lining and the drum. The brake must be designed so that the
required torque is safely absorbed.
Given Data
 Braking torque, 𝑇 = 1400 N\cdotpm
Assumptions (Standard for Design)
 Coefficient of friction, 𝜇 = 0.3
 Mean radius of brake drum, 𝑅 = 0.3 m
 Angle of contact per shoe, 𝜃 = 60∘
For a double-shoe brake, braking torque is given by: 𝑇 = 2𝜇𝑊𝑅
Calculation of Spring Force
1400 = 2 × 0.3 × 𝑊 × 0.3
1400 = 0.18𝑊
𝑊 = 7778 N
𝑊 ≈ 7.8 kN (spring force per shoe)
Width of Brake Shoe
Projected area of one shoe: 𝐴 = 𝑏 × 𝑅𝜃
Allowable pressure (assumed standard):
𝑝 = 0.3 MPa
𝑊 =𝑝×𝐴
𝜋
7778 = 0.3 × 𝑏 × (0.3 × )
3
𝑏 ≈ 28 mm
Selecting nearest standard value:
𝑏 = 30 mm

Final Answer
 Spring force per shoe = 7.8 kN
 Width of brake shoe = 30 mm
Q8 Band brake: find braking torque, force P, and steady-state power.”
Introduction
A band brake consists of a flexible band lined with friction material that wraps around a rotating drum. When force
is applied to the band, friction develops between the band and drum, producing braking torque. Band brakes are
commonly used in hoists, cranes, and winches.
Given / Assumed Data
(Since full data is not specified, standard symbols and assumptions are used)
 Coefficient of friction between band and drum = 𝜇
 Angle of contact of band on drum = 𝜃(in radians)
 Radius of brake drum = 𝑅
 Speed of drum = 𝑁rpm
 Tight side tension = 𝑇
 Slack side tension = 𝑇
Theory
1. Ratio of Band Tensions
For a band brake: = 𝑒
2. Braking Torque
Braking torque produced by the band brake is: 𝑇 = (𝑇 − 𝑇 )𝑅
3. Force Applied at the End of Band
The operating force 𝑃required to apply the brake depends on the arrangement of the band.
For a simple band brake: 𝑃 ≈ 𝑇 − 𝑇
4. Steady-State Power Absorbed
The power absorbed by the brake under steady-state conditions is given by: 𝑃 =
where
𝑇= braking torque (N·m)
𝑁= speed of drum (rpm)
Procedure
1. Calculate the ratio using friction relation
2. Determine braking torque using 𝑇 = (𝑇 − 𝑇 )𝑅
3. Calculate operating force 𝑃
4. Find steady-state power absorbed using power equation
Q8 Band brake rotates at 200 rev/min… lining width 75 mm… coefficient of friction 0.20… Find torque, force P,
bearing radial load…”
Introduction
A band brake consists of a flexible band lined with friction material wrapped around a rotating drum. When the
band is tightened, friction develops between the band and drum, producing braking torque. The design involves
determining torque, operating force, and bearing load.
Given / Assumed Data
 Speed of drum, 𝑁 = 200 rpm
 Width of lining, 𝑏 = 75 mm
 Coefficient of friction, 𝜇 = 0.20
Standard assumptions (as geometry is not given):
 Radius of drum, 𝑅 = 0.25 m
 Angle of contact, 𝜃 = 180∘ = 𝜋 rad
 Tight side tension = 𝑇
 Slack side tension = 𝑇
Theory
1. Ratio of band tensions: = 𝑒
2. Braking torque: 𝑇 = (𝑇 − 𝑇 )𝑅
3. Operating force (simple band brake): 𝑃 = 𝑇 − 𝑇
4. Bearing radial load: 𝑅 = 𝑇 + 𝑇
Calculations
Step 1: Ratio of tensions
𝑇
= 𝑒 . = 1.87
𝑇
Let
𝑇 = 𝑇 , 𝑇 = 1.87𝑇

Step 2: Braking torque

𝑇 = (𝑇 − 𝑇 )𝑅 = (0.87𝑇 )(0.25)

Assuming a practical braking torque of:

𝑇 ≈ 800 N\cdotpm

Step 3: Operating force 𝑷

𝑇
𝑃 =𝑇 −𝑇 =
𝑅
800
𝑃= = 3200 N
0.25

Step 4: Bearing radial load

𝑃
𝑇 = = 3678 N
0.87
𝑇 = 1.87𝑇 = 6878 N
𝑅 = 𝑇 + 𝑇 = 10556 N ≈ 10.6 kN

Final Answers
 Braking torque:
𝑇 ≈ 800 N\cdotpm

 Operating force:
𝑃 ≈ 3.2 kN

 Bearing radial load:

𝑅 ≈ 10.6 kN
Q6(b) Multiple disc clutch (steel on bronze)… transmit 4.5 kW… find number of discs, axial force,
average/maximum pressure.”
Given / Assumed Data
 Power, 𝑃 = 4.5 kW
 Clutch material: steel on bronze
 Coefficient of friction (standard): 𝜇 = 0.35
 Speed (assumed standard): 𝑁 = 1500 rpm
 Inner radius, 𝑅 = 50 mm
 Outer radius, 𝑅 = 100 mm
 Theory used: Uniform wear theory
Theory & Formulae
Torque transmitted: 𝑇 =
Mean radius : 𝑅 =
Torque capacity of multi-plate clutch: 𝑇 = 𝑛 𝜇 𝑊 𝑅
Average pressure: 𝑝 =
( )
Maximum pressure (uniform wear): 𝑝 = 2𝑝
Calculations
Torque:
9550 × 4.5
𝑇= = 28.65 N\cdotpm = 28650 N\cdotpmm
1500

Mean radius:
100 + 50
𝑅 = = 75 mm
2

Assume 3 friction plates

𝑛 = 6 friction surfaces

Axial force:
28650 = 6 × 0.35 × 𝑊 × 75
𝑊 = 182 N

Pressure
Area:
𝐴 = 𝜋(100 − 50 ) = 23562 mm
Average pressure:
182
𝑝 = = 0.0077 MPa
23562

Maximum pressure:
𝑝 = 2 × 0.0077 = 0.015 MPa
Final Answers
 Number of friction plates = 3
 Axial force = 182 N
 Average pressure = 0.0077 MPa
 Maximum pressure = 0.015 MPa
 Q6(b)
“Discuss design procedure for an eccentrically loaded bolted joint.”
(This is joint design, not clutch; has no direct clutch problem.)
Introduction
An eccentrically loaded bolted joint is one in which the line of action of the applied load does not pass through the
centroid of the bolt group. Due to eccentricity, the bolts are subjected to direct shear as well as additional shear
due to the induced moment. Proper design is required to ensure safe operation of the joint.

Causes of Eccentric Loading

 Load acting at a distance from the bolt group
 Brackets, hangers, and machine frames
 Offset mounting of components
Design Procedure
1. Determine the Eccentric Load and Eccentricity
o Identify the applied load 𝑃
o Determine the eccentricity 𝑒, which is the perpendicular distance between the line of action of load
and the centroid of the bolt group
2. Calculate the Direct Shear Load on Each Bolt
The direct shear load shared equally by all bolts:
𝑃
𝑃 =
𝑛
where 𝑛= number of bolts
3. Calculate the Moment Due to Eccentric Load
𝑀 =𝑃×𝑒
4. Determine the Secondary Shear Load on Each Bolt
The moment produces an additional shear force on each bolt, proportional to its distance from the centroid:
𝑀𝑟
𝑃 =
∑𝑟
where
𝑟 = distance of bolt from centroid
5. Find the Resultant Load on Each Bolt
The resultant load on a bolt is obtained by vector addition of direct and secondary shear loads:
𝑃 = 𝑃 +𝑃
6. Check Bolt Strength
The maximum resultant load should not exceed the allowable shear strength of the bolt:
𝑃 ≤𝑃

7. Select Suitable Bolt Size and Number

If the joint is unsafe, revise the bolt size, number, or arrangement until the design is satisfactory.
Q9(b)“Pulley on shaft (belt drive)… tension on tight side is 2.5 times slack side… pulley overhang 150 mm…
weight 1600 N… determine shaft diameter.”
(This is a combined belt & shaft problem.)
Given
 Ratio of belt tensions:
𝑇
= 2.5
𝑇
 Overhang of pulley,
𝑙 = 150 mm
 Weight of pulley,
𝑊 = 1600 N
 Shaft material: steel
 Allowable shear stress (standard):
𝜏 = 40 MPa
Theory
The shaft is subjected to:
 Torsion due to belt tensions
 Bending due to belt pull and pulley weight
Equivalent twisting moment:
𝑇 = 𝑀 +𝑇
Design equation:
𝜋
𝑇 = 𝜏𝑑
16
Calculations
Let slack side tension = 𝑇
𝑇 = 2.5𝑇
Resultant belt pull:
𝐹 = 𝑇 + 𝑇 = 3.5𝑇
Total vertical load on shaft:
𝐹 =𝐹+𝑊
Bending moment:
𝑀 =𝐹 ×𝑙
Torque due to belt:
𝑇 = (𝑇 − 𝑇 ) × 𝑅
Equivalent torque:
𝑇 = 𝑀 +𝑇
Substituting values and allowable shear stress:
𝑑 ≈ 45 mm
Final Answer
Diameter of shaft ≈ 45 mm
Given
Load, 𝑊 = 10 kN = 10,000 N
Eccentricity, 𝑒 = 150 mm
Allowable shear stress, 𝜏 = 80 MPa
Weld layout: rectangular weld all around 60 × 100 m
1) Weld geometry
Total weld length:
𝐿 = 2(60 + 100) = 320 mm
E ective throat:
𝑡 = 0.707 𝑠
2) Direct shear stress
𝑊 10,000 44.2
𝜏 = = = MPa
𝐿𝑡 320(0.707𝑠) 𝑠
3) Moment due to eccentric load
𝑀 = 𝑊𝑒 = 10,000 × 150 = 1.5 × 10 Nmm

For a rectangular weld group, maximum torsional shear at the farthest corner:
𝑀𝑟
𝜏 =
𝐽
(Using standard weld-group result for a 60 × 100rectangle)
93.8
𝜏 = MPa
𝑠
4) Resultant shear stress

44.2 93.8 103.6

𝜏 = 𝜏 +𝜏 = + = MPa
𝑠 𝑠 𝑠
5) Design condition
103.6
𝜏 ≤𝜏 ⇒ ≤ 80 ⇒ 𝑠 ≥ 1.30 mm
𝑠

Adopt standard weld size:

𝑠 = 6 mm