DMM – 1

MID II Assignment and Exam Questions

Assignment should be submitted before DMM Mid Exam

Unit – 4:

1. It is required to design a knuckle joint to connect circular shafts subjected to

an axial force of 50 kN. The rods are coaxial and a small amount of angular
movement between their axes is permissible. Design the joint and specify
the dimensions of its components. The allowable tensile, compressive and
shear stress in the rod and pin material is limited to 80MPa, 100MPa and
40MPa respectively.

2. A line shaft is to transmit 30 KW at 160 rpm. It is driven by a motor placed

directly under it by means of a belt running on a 1m diameter pulley keyed
to the end of the shaft. The tension in the tight side of the belt is 2.5 times
that of the slack side and the centre of pulley overhangs 150 mm beyond the
centre line of the end bearing. Determine the diameter of the shaft, if the
allowable shear stress is 56MPa and the pulley weighs 1600 N.
3. A mild steel shaft transmits 20 KW at 200 rpm. It carries a central load of
900 N and is simply supported between the bearings 2.5 m apart. Determine
the size of the shaft, if the allowable shear stress is 42 MPa and the
maximum tensile or compressive stress is not to exceed 56 MPa. What size
of the shaft will be required, if it is subjected to gradually applied loads?
4. A square key is to be used to key a gear to a 35 mm diameter shaft. The
length of the hub of the gear is 60mm. Both shaft and key are made of same
material, having an allowable shear stress of 55Mpa. What are the minimum
dimensions of the key if 400N-m of torque is to be transmitted?

5. Design a gib and cotter joint to carry a load of 35KN. Take σt = 20MPa, τ =
15MPa. Assume that the Gib, Cotter and Rod are made of same material.

Unit – 5
 1. Design a Cast Iron flange coupling for a steel shaft transmitting 15 KW at
200 rpm 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 % greater than the full load torque.
The shear stress for Cast Iron is 14 MPa.
2. Design a Muff coupling which is used to connect two steel shafts
transmitting 40 KW at 350 rpm. The material for the shaft 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 cast iron for
which the allowable shear stress may be assumed as 15MPa.
3. Design a cast iron protective type flange coupling to connect two shafts in
order to transmit 7.5kW at 720rpm. The following permissible stresses may
be used:
Permissible shear stress for shaft, bolt and key material = 33MPa
Permissible crushing stress for shaft, bolt and key material = 60MPa
Permissible shear stress for the cast iron = 15MPa.
4. Design a rigid type of flange coupling to connect two shafts. The input shaft
transmits 37.5kW power at 180 rpm to the output shaft through the coupling.
The service factor for the application is 1.5. The design torque is 1.5times of
rated torque. Select suitable materials for various parts of the coupling,
design the coupling and specify the dimensions of the components.

5. Design a rigid type of coupling to connect two shafts transmits 37.5 KW

power at 180rpm to the output shaft through the coupling. The service factor
for the application is 1.5. The allowable stresses are given below.
(i) Shaft – τ = 76 MPa
(ii) Key and Bolt – τ = 80MPa, σc = 240MPa
(iii) Flange – τ = 16 MPa.

Unit – 6
1. Design a helical spring for a spring loaded safety valve for the following
conditions:
Diameter of valve seat = 65 mm, operating pressure = 0.7 N/mm2, Maximum
pressure when the valve blows off freely = 0.75 N/mm2, Maximum lift of the
valve when the pressure rises from 0.7 to 0.75 N/mm2 = 3.5 mm, Maximum
allowable stress = 550 MPa, Modulus of rigidity = 84 KN/mm2, Spring index = 6.

2. A rail wagon of mass 20 tonnes is moving with a velocity of 2 m/s. It is

brought to rest by two buffers with springs of 300 mm diameter. The
maximum deflection of springs is 250 mm. The allowable shear stress in the
spring material is 600 MPa. Design the springs for the buffers.

3. A helical compression spring made of oil tempered carbon steel, is subjected

to a load which varies from 400 N to 1000 N. The spring index is 6 and the
design factor of safety is 1.25.If the yield stress in shear is 770 MPa and
endurance stress in shear is 350MPa. Find: 1) Size of the spring wire 2)
Diameters of the spring 3) Number of turns of the spring and 4) Free length
of the spring. The compression of the spring at the maximum load is 30 mm.
The modulus of rigidity for the spring material may be taken as 80 kN/mm2.
thickness and width of the steel spring leaves. The ratio of the total depth to
the width of the spring is 3.Also determine the deflection of the spring.

4. Find the maximum shear stress and deflection induced in a helical spring of
the following specifications, if it has to absorb 1000 N-m of energy. Mean
diameter of spring = 100 mm; Diameter of steel wire, used for making the
spring = 20 mm; Number of coils = 30; Modulus of rigidity of steel = 85
kN/mm2.

5. Design a helical compression spring to carry a load of 1.5KN with the

deflection of 40mm. Spring index is 5. τ = 400MPa, G = 0.79 x 105 N/mm2