ME 6503 DESIGN OF MACHINE ELEMENTS

QUESTION BANK

PART-A

1. Discuss the function of a coupling. Give at least three practical applications.

2. Mention the material properties of shafts.
3. What do you understand by the term Torsional rigidity?
4. Under what circumstances flexible couplings are used?
5. Why a hollow shaft has greater strength and stiffness than a solid shaft of equal weight?
6. List out the various failures of knuckle joints.
7. A shaft of 750 mm long is subjected to shear stress of 40 MPa and has an angle of twist equal
to 0.017 radian. Determine the diameter of the shaft. Take G=80 GPa.
8. Reasons for replacing riveted joint by a welded joint in modern equipment?
9. Properly made butt welds are equal or better strength than the plate. Justify.
10. What is meant by woodruff keys?
11. What do you understand by the term torsional rigidity?
12. Define the term of lateral rigidity.
13. Define the term of lateral rigidity.
14. Write short notes on feather key
15. A 50 mm diameter solid shaft is welded to a flat plate by 10 mm fillet
weld as shown in fig. Find the maximum torque that the welded joint
can sustain if the maximum shear stress intensity in the weld material is
not to exceed 80 MPa.
PART-A
1. A transmission shaft is supported on two bearings which are 1m apart power is supplied to
shaft by means of a flexible coupling which is located to the left of left hand bearing. Power is
transmitted from the shaft by means of a belt pulley, 250 mm diameter. Which is located at a
distance of 300 mm from the left hand bearing. The mass of the pulley is 20 kg and the ratio of
belt tension on tight and slack sides is 2:1. The belt tension act vertically downward. The shaft
is made of steel with yield stress 300 N/mm2 and the factor of safety is 3. Determine the shaft
diameter, if it transmits 10kW power at 360 rpm from the coupling to the pulley.
2. Design a shaft to transmit power from an electric motor to a lathe head stock througha pulley
by means of a belt drive. The pulley weighs 200 N and is located at 300 mm from the centre of
the bearing. The diameter of the pulley is 200 mm and the maximum power transmitted is 1
kW at 120 rpm. The angle of lap of the belt is 180° and coefficient of friction between the belt
and the pulley is 0.3. The shock arid fatigue factors for bending and twisting are 1.5 and 2
respectively. The allowable shear stress in the shaft may be taken as 35 MPa.
3. A shaft is supported on bearings A and B, 800 mm between centres. A 20°straight tooth spur
gear having 600 mm pitch diameter, is located 200 mm to the right of the left hand bearing A,
 and a 700 mm diameter pulley is mounted 250 mm towards the left of bearing B. The gear is
driven by a pinion with a downward tangential force while the pulley drives a horizontal belt
having 180° angle of wrap. The pulley also serves as a flywheel and weighs 2000 N. The
maximum belt tension is 3000 N and the tension ratio is 3 : 1. Determine the maximum
bending moment and the necessary shaft diameter if the allowable shear stress of the material
is 40 MPa.
4. Design and make a neat dimensioned sketch of a muff coupling which is used to connect two
steel shafts transmitting 40 KW at 350 r.p.m.The material for the shafts and key is plain carbon
steel for which allowable shear and crushing stresses may be taken as 40MPa and 80MPa
respectively. The material for the muff is cat iron for which the allowable shear stress may be
assumed as 15MPa.
5. Design a clamp coupling to transmit 30 kW at 100 r.p.m. The allowable shear stress for the
shaft and key is 40 MPa and the number of bolts connecting the two halves are six. The
permissible tensile stress for the bolts is 70 MPa. The coefficient of friction between the muff
and the shaft surface may be taken as 0.3.
6. Design and draw a protective type of cast iron flange coupling for a steel shaft transmitting 15
kW at 200 r.p.m. and having an allowable shear stress of 40 MPa. The working stress in the
bolts should not exceed 30 MPa. Assume that the same material is used for shaft and key and
that the crushing stress is twice the value of its shear stress. The maximum torque is 25%
geater than the full load torque. The shear stress for cast iron is 14 MPa.
7. Design and draw a cast iron flange coupling for a mild steel shaft transmitting 90 kW at 250
r.p.m. The allowable shear stress in the shaft is 40 MPa and the angle of twist is not to exceed
1° in a length of 20 diameters. The allowable shear stress in the coupling bolts is 30 MPa. Take
G = 84kN/mm2.
8. Design a bushed-pin type of flexible coupling to connect a pump shaft to amotor shaft
transmitting 32 kW at 960 r.p.m. The overall torque is 20 percent more than mean torque. The
material properties are as follows :(a) The allowable shear and crushing stress for shaft and
key material is 40 MPa and80 MPa respectively.(b) The allowable shear stress for cast iron is 15
MPa.(c) The allowable bearing pressure for rubber bush is 0.8 N/mm2.(d) The material of the
pin is same as that of shaft and key.Draw neat sketch of the coupling.
9. Design a knuckle joint to transmit 150 kN. The design stress may be taken as 75 MPa in
tension, 60 MPa in shear and 150 MPa in compression.
10. It is required to design a knuckle joint to connect two circular rods subjected to an axial tensile
force of 50 kN. The rods are co-axial and a small amount of angular movement between their
axes is permissible. Design the joint and specify the dimensions of its components. Select
suitable materials for the parts. Assume rod materials as 30CB and FOS = 5.
11. Find the maximum shear stress induced in the weld of 6 mm size when a channel, as shown in
fig, is welded to plate and loaded with 20 kN force at a distance of 200 mm.

12. The bracket, as shown in Fig., is designed to carry a

dead weight of P = 15 kN. What sizes of the fillet
welds are required at the top and bottom of the
bracket? Assume the forces act through the points A
and B. The welds are produced by shielded arc
welding process with a permissible strength of 150
MPa.

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