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QUESTION BANK
SUBJECT :DESIGN OF MACHINE ELEMENT
SEM/YEAR :V SEM/III YEAR

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UNIT I - STEADY STRESSES AND VARIABLE STRESSES IN MACHINE MEMBERS

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Introduction to the design process - factors influencing machine design, selection of materials based on mechanical
properties - Preferred numbers, fits and tolerances – Direct, Bending and torsional stress equations – Impact and shock
loading – calculation of principle stresses for various load combinations, eccentric loading – curved beams – crane hook and
‘C’ frame- Factor of safety - theories of failure – Design based on strength and stiffness – stress concentration – Design for

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variable loading

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PART - A (2Marks)
S.No QUESTIONS LEVEL COMPETENCE
1. Define GD&T. BTL1 Remember
2. Define Interchange ability. BTL2 Understand
3.
4.
5.
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Define shock factor and what does it indicate.
Distinguish hardness and toughness.
What are preferred numbers?
BTL4
BTL1
BTL1
Analyze
Remember
Remember
6. Brief about Soderberg and Goodman lines. BTL2 Understand
Why nonsymmetrical I and T sections are preferred in design of curved BTL1
ad
Remember
7. beams?
8. What do you understand by the nominal size and basic size? BTL1 Remember
9. Define "hole basic system" and "shaft basic system". BTL2 Understand
10. List out the various phases of design process. BTL4 Analyze
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11. Define modulus of resilience and proof resilience. BTL1 Remember

12. How the machine design may be classified? BTL2 Understand
13. What is an S-N Curve? BTL1 Remember
14. Describe the common materials used in mechanical engineering design. BTL3 Apply
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15. List the important factors that influence the magnitude of factor of BTL1 Remember
safety.
16. What is meant by working stress and how it is calculated from the BTL6 Create
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ultimate stress or yield stress of material?

17. Give some methods of reducing stress concentration. BTL4 Analyze
Define notch sensitivity. State the relation between stress concentration BTL1 Remember
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18. factor, fatigue stress concentration factor and notch sensitivity.

19. Differentiate between repeated stress and reversed stress. BTL2 Understand
20. Which theory of failure is suitable for the design of brittle materials? BTL1 Remember

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PART - B (13 Marks)
S.No QUESTIONS LEVEL COMPETENCE
A hypothetical machine member by 50mm in diameter and 250mm in
diameter and 250mm long is supported in one end as cantilever is
subjected to various types of loadings as given below. Find the principal
stress and maximum shear stress in each case.

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i. Axial load 15 KN

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Evaluate
1 ii. Transverse load 3KN at the free end
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iii. Twisting moment of 1KN-m at the free end, clockwise, while

viewing from free end side

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iv. (i) and (ii) together

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v. (i) (ii) and (iii) together (13)
A wall crane with a pin - joint tie rod is as shown in Fig. The crane hook
is to take a maximum load 35KN, when the load is at a distance of 2m
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from the wall. the tie rod and pin are made of steel FeG 250 (Syt =
250N/mm2) and the factor of safety is 5. Calculate the diameter of the tie
rod and the pin.
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Apply
2 BTL3
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An overhang crank with pin and shaft is shown in Fig. A tangential load
of 15kN acts on the crank pin. Determine the maximum principal stress
and the maximum shear stress at the centre of the crankshaft bearing (13)

Evaluate

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3 BTL5

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A mild steel bracket as shown in Fig. is subjected to a pull of 6000N
acting at 45˚ to its horizontal axis. The bracket has a rectangular section
whose depth is twice the thickness. Determine the cross-sectional
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dimensions of the bracket, if the permissible stress in the materials of the
bracket is limited to 60 MPa. (13)

Evaluate
4 BTL5
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(a) The frame of a punch press is shown in fig. Find the stress at the inner
and outer surface at section X-X of the frame, if W=5000N. (7)
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Evaluate
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5 BTL5

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b. what is factor of safety? List the factors to be considered while deciding

the factor of safety. ( 6)
The load on a bolt consists of an axial pull of 10kN together with a
transverse shear force of 5kN. Find the diameter of bolt required

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according to 1. Maximum principle stress theory 2. Maximum shear stress Remember
6 BTL1

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theory; 3. Maximum principle strain theory; 4. Maximum strain energy
theory; and 5. Maximum distortion energy theory. Take permissible
tensile stress at elastic limit = 100 MPa and Poisson’s ratio = 0.3. (13)
A mild steel shaft of 50mm diameter is subjected to a bending moment of

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2000 N-m and a torque T. If the yield point of the steel in tension is 200

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MPa, Calculate the maximum value of this torque without causing Evaluate
7 yielding of the shaft according to 1. The Maximum principle stress; 2. The
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maximum shear stress and 3. The maximum distortion strain energy

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theory of yielding. (13)
Calculate the maximum stress induced in the following cases taking stress
concentration into account:
1. A rectangular plate 60 mm × 10 mm with a hole 12 diameter as
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shown in Fig. (a) and subjected to a tensile load of 12 kN. (8)
2. A stepped shaft as shown in Fig. (b) and carrying a tensile load of 12
Apply
8 kN. (5) BTL3
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A machine component is subjected to a flexural stress which fluctuates

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between +300 MN/m2 and -150 MN/m2. Determine the value of

minimum ultimate strength according to 1. Gerber relation; 2. Modified Apply
9 BTL3
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Goodman relation; and 3. Soderberg relation. Take yield strength = 0.55

Ultimate strength; Endurance strength= 0.5 Ultimate strength and factor of
safety = 2. (13)
A bar of circular cross-section is subjected to alternating tensile forces Evaluate
10 varying from a minimum of 200kN to maximum of 500kN. It is to be
BTL5

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manufactured of a material with an ultimate tensile strength of 900MPa.
and an endurance limit of 700 MPa. Determine the diameter of bar using
safety factors of 3.5 Related to ultimate tensile strength and 4 related to
endurance limit and a stress concentration factor of 1.65 for fatigue load.
Use Goodman straight line as basis for design. (13)

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A circular bar of 500mm length is supported freely at its two ends. It is

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acted upon by a central concentrated cyclic load having a minimum value
of 20kN and a maximum value of 50kN. Determine the diameter of bar by Evaluate
11 taking a factor of safety of 1.5, size effect of 0.85, surface finish of 0.9.
BTL5

The material properties of bar are given by ultimate strength of 650 MPa,

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yield strength of 500 MPa and endurance strength of 350 MPa. (13)

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A cantilever beam made of cold drawn carbon steel of circular cross-
section as shown in fig. is subjected to a load which varies from –F to 3F.
Determine the maximum load that this member can withstand for an
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indefinite life using a factor of safety as 2. The theoretical stress
concentration factor is 1.42 and the notch sensitivity is 0.9. Assume the
following values: Ultimate stress = 550 MPa. Yield Stress = 470 MPa.
Endurance limit = 275 MPa. Size factor = 0.85. Surface finish factor =
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0.89. (13) Evaluate
12 BTL5
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A pulley is keyed to a shaft midway between two bearings. The shaft is

made of cold drawn steel for which the ultimate strength is 550 MPa and
the yield strength is 400 MPa. The bending moment at the pulley varies
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from -150N.m to +400 N.m as the torque on the shaft varies from -50N.m Evaluate
13 BTL5
to 150 N.m. Obtain the diameter of the shaft for an indefinite life. The
stress concentration factors for the keyway at the pulley in bending and in
torsion are 1.6 and 1.3 respectively. Take the following values. Factor of

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safety=1.5, Load correction factors=1 and 0.6 in torsion, size effect
factor=0.85 and surface effect factor=0.88 . (13)
A steel rod is subjected to a reversed axial load of 180KN.Find the
diameter of the rod for a factor of safety of 2.Neglect the column effect.
The material has an ultimate tensile strength of 1070 MPa and yield

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strength of 910 MPa. The endurance limit in reversed bending may be
Evaluate

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14 assumed to be one half of the ultimate strength. Other correction factors BTL5

may be taken as follows. For axial loading=0.7, For machined

surface=0.8,For size=0.85, For stress concentration=1.0 (13)

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PART-C (15 Marks)
(i) Which theory is in better agreement for predicting the failure of ductile
component? Sketch the schematic representation under bi-axial stresses
for the theory. Create
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(ii) What is mean by safety factor?
(iii) Justify that the wheelchair design in a multidisciplinary endeavor.
Determine the stress at point A and B split ring shown in fig. If a
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compressive force = 20 KN is applied point.

Evaluate
2 BTL5
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A solid circular shaft of diameter 45 mm is loaded by bending moment

650Nm, torque 900 Nm and an axial tensile force of 30KN. The shaft
material is ductile with yield strength of 280 MPa. Determine the factor of Create
3 BTL6
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safety according to Maximum Principal stress, Tresca and Von misses

theories of failure.
A 50 mm wide, 5mm high rectangular plate has 5mm diameter central Evaluate
4 hole. The allowable tensile stress is 700 MPa. Find (i) The maximum
BTL5

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tensile force that can be applied (ii) the maximum bending moment that
can be applied to reach the maximum stress (iii) the maximum tensile
force and the maximum bending moment if the hole is not present.
Express the results as a ratio when compared to parts (i) and (ii)

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UNIT II - SHAFTS AND COUPLINGS
Design of solid and hollow shafts based on strength, rigidity and critical speed – Keys, keyways and splines -
Rigid and flexible couplings.
PART - A (2Marks)
S.No QUESTIONS LEVEL COMPETENCE
1. When the shaft is subjected to fluctuating loads? BTL2 Understand

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2. Point out, how the shaft is designed when it is subjected to bending Remember
BTL1

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moment only?
3. Write the advantages that hollow shafts offer as compared to solid shafts. BTL1 Remember
4. Define the term critical speed of a shaft. BTL1 Remember
5. Distinguish clearly, giving examples between pin, axle and shaft. BTL4 Analyze

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6. List out types of stresses are induced in shafts. BTL1 Remember

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7. A hollow shaft has greater strength and stiffness than solid shaft of equal Analyze
weight. Explain. BTL4

8. Under what circumstances are hollow shaft preferred over solid shaft? BTL2 Understand
9. What do you understand by torsional rigidity and lateral rigidity? BTL4 Analyze
10.
11.
12.
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List the different types of sunk keys and draw any one.
Different between rigid and flexible couplings.
State the reasons for which the coupling are located near the bearings.
BTL2
BTL2
BTL3
Understand
Understand
Apply
13. Explain how is the strength of a shaft affected by the keyway? BTL2 Understand
14. Under what circumstances flexible coupling are used? BTL4 Analyze
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15. Discuss the function of a coupling. Give at least three practical Evaluate
applications. BTL5
16. What are possible modes of failure of the pin (bolt) in a flexible Analyze
BTL4
coupling? Explain.
17. Differentiate between keys and splines. BTL2 Understand
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18. Discuss forces on keys. BTL5 Evaluate

19. Why are two universal joints often used when there is angular Analyze
misalignment between two shafts? BTL4
20. What is key? State its function
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Analyze
BTL4

PART - B (13 Marks)

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S.No QUESTIONS LEVEL COMPETENCE

A mild steel shaft transmits 20kW at 200 rpm. It carries a central load of
900N and is simply supported between the bearings 2.5m apart.
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Determine the size of the shaft, if the allowable shear stress is 42 MPa and Evaluate
1 the maximum tensile or compressive stress is not to exceed 56MPa.What
BTL5

size of the shaft will be required, if it is subjected to gradually applied

loads? (13)

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A transmission shaft supporting a helical gear B and an overhang bevel
gear D is shown in fig. The shaft is mounted on two bearings A and C.
The pitch circle diameter of the helical gear is 450 mm and the diameter
of the bevel gear at the force is 450mm. Power is transmitted from the
helical gear to the bevel gear. The gears are keyed to the shaft. The

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material of the shaft is steel 45C8 (Sut =600 and Syt = 380 N/mm2). The

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factors Kb and Kt of ASME code are 2.0 and 1.5 respectively. Determine
the shaft diameter using the ASME code.
Apply
2 BTL3

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A shaft is supported on bearing A and B, 800 mm between centers. A 20˚
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straight tooth spur gear having 600mm pitch diameter, is located 200 mm
to the right of the left had 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
Apply
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3 horizontal belt having 180˚ angle of wrap. The pulley also serves as a BTL3
flywheel and weights 2000N. The maximum belt tension is 3000 N and
the tension ratio is 3:1. Determine the maximum bending moment and the
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necessary shaft diameter if the allowable shear stress of the material is 40

MPa. (13)
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A steel solid shaft transmitting 15kW at 200 rpm is supported on two
bearing 750 mm apart and has two gears keyed to it. The pinion having 30
teeth of 5mm module is located 100 mm to the left of the right hand
bearing and delivers power horizontally to the right. The gear having 100 Evaluate
4 BTL5
teeth of 5mm module is located 150mm to the right of the left hand

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bearing and receives the power in vertical direction below. Using an

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allowable stress of 54MPa in shear, determine the diameter of the shaft.
A hollow shaft of 0.5m outside diameter and 0.3m inside diameter is used
to drive a propeller of a marine vessel. The shaft is mounted on bearings
6m apart and it transmits 5600kW at 150 rpm. The maximum axial

.
Apply
5 propeller shaft is 500kN and the shaft weighs 70kN.Determine BTL3

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(i).The maximum shear stress developed in the shaft
(ii).The angular twist between the bearings. (13)
A section of commercial shafting 2m long between bearings carries a
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1000N pulley at its midpoint as shown in fig. The pulley is keyed to the
shaft and receives 30 KW at 150 rev/min which is transmitted to a flexible
coupling just outside the right bearing. the belt drive is horizontal and
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some of the belt tensions is 8000 N. Assume Kt = Kb = 1.5. Calculate the
necessary shaft diameter and determine the angle of twist between
bearings. G=80 GN/m2. (13)
Evaluate
6 BTL5
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Design a shaft to transmit power from an electric motor to a lathe head

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stock through a pulley be means of a belt drive. The pulley weights 200N
and is located at 300 mm from the centre of the bearing. The diameter of Create
7 BTL6
the pulley is 200 mm and the maximum power transmitted is 1 kW at 120
rpm. The angle of the belt is 180˚ and coefficient of friction between the

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belt and the pulley is 0.3. The shock and fatigue factors for bending and
twisting are 1.5 and 2.0 respectively. The allowable shear stress in the
shaft may be taken as 35 MPa. (13)
A shaft mad of AISI 1030 cold drawn steel transmits 50 KW at 900 rpm Create
8 through a gear. select and appropriate square key for the gear. (13)
BTL6

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A rigid coupling is used to transmit 50KW power at 300 rpm. There are

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six bolts the outer diameter of the flanges is 220 mm, while the recess
diameter is 150mm. The coefficient of friction between the flanges is 0.15 Create
9 mm. The bolts are made of steel 45C8 (Syt = 380 N/mm2) and the factor of
BTL6

safety is 3. Determine the diameter of the bolts. Assume that the bolts are

.
fitted in large clearance holes. (13)

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Design a cast iron protective type flange coupling to transmit 15kW at 900
rpm from an electric motor to a compressor. The service factor may be
assumed s 1.35.The following permissible stresses may be used. Shear Apply
10 ee BTL3
stress for shaft, bolt and key material=40MPa,Crushing stress for bolt and
key=80 MPa, Shear stress for cast iron=8 MPa. (13)
Design a cast iron flange coupling for a mild steel shaft transmitting 90
kW at 250 rpm, the allowable shear stress in the shaft is 40 MPa and the
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Create
11 angle of twist is not to exceed 1˚ in a length of 20 meters. The allowable
BTL6

shear stress in the coupling bolt is 30 MPa. Take G = 84 kN/mm2 (13)

Two 35 mm shaft are connected by a flanged coupling. The flanges are
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fitted with 6 bolts on 125 mm bolt circle. The shafts transmit a torque of
800 N-m at 350 rpm. For the safe stresses mentioned below, calculate 1.
Diameter of bolts; 2. Thickness of flanges; 3. Key dimensions; 4. Hub Apply
12 BTL3
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length; and 5. Power transmitted. Safe shear stress for the shaft material =
63 MPa; Safe stress for bolt material = 56 MPa; Safe stress for cast iron
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coupling = 10 MPa; Safe stress for key material = 46 MPa. (13)

Design a bushed-pin type of flexible coupling to connect a pump shaft to a
motor shaft transmitting 32kW at 960 rpm. The overall torque is 20%
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more than mean torque. The material properties are as follows. The Create
13 allowable shear and crushing stress for the shaft and key material is 40
BTL6

MPa and 80 MPa. The allowable shear stress for cast iron is 15 MPa. The
allowable bearing pressure for rubber bush is 0.8N/mm2.The material of

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the pin is same as that of shaft and key. (13)
Design and draw a protective type of cast iron flange coupling for a steel
shaft transmitting 15kW 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 the shaft and key and that the Create
14 BTL6

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crushing stress is twice the value of its shear stress. The maximum torque

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is 25% greater than the full load torque. The shear stress for cast iron is 14
MPa. (13)

PART-C (15 Marks)

A shaft is supported by two bearings placed 1100 mm apart . A pulley of

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diameter 620 mm is keyed at 400 mm to the right of the left hand bearing

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and this drives a pulley directly below it with a maximum tension of
2.75KN. Another pulley of diameter 400 mm is placed 200 mm to the left
Evaluate
1 of the right hand bearing and is driven with a motor placed horizontally to BTL5
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the right. The angle of contact of the pulleys is 180˚ and the coefficient of
friction between the belt and the pulleys is 0.3. Find the diameter of the
shaft Assume Kb =3, Kt = 2.5, Syt=190 MPa, SUt=300 MPa.
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A horizontal shaft AD supported in bearings at A and B and carrying Evaluate
pulleys at C and D is to transmit 75 kW at 500 rpm from drive pulley D to
off-take pulley C as shown in fig. calculate the diameter of shaft. The data
given is P1 = 2P2 (both horizontal) Q1 = 2 Q2 (both vertical) radius of
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pulley C = 220 mm, radius of pulley D = 160mm allowable shear stress =

45 MPa.
2 BTL5
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Design a rectangular key for the following application: A shaft 65 mm

diameter transmits power at maximum shear stress of 67 MPa. The shear Create
3 BTL6
stress in the key should not exceed 75% of the stress developed in the

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shaft. The key should be least 2.5 times strong in crushing compared to
shear failure of the key.
Design a muff coupling to connect two shafts transmitting 40KW at 120
rpm. The permissible shear and crushing stress for the shaft and key
material (mild steel) are 30 MPa. and 80MPa. respectively. The material BTL6 Create
4

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of muff is cast iron with permissible shear stress of 15 MPa. Assume that

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the maximum torque transmitted is 25 per cent greater than mean torque.

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UNIT III - TEMPORARY AND PERMANENT JOINTS

Threaded fastners - Bolted joints including eccentric loading, Knuckle joints, Cotter joints – Welded joints,
riveted joints for structures - theory of bonded joints
PART - A (2Marks)
S.No QUESTIONS LEVEL COMPETENCE

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1. Explain how is a bolt designated? BTL1 Remember

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2. Discuss, why are ACME treads preferred over square thread for power Understand
screw? BTL2
3. What do you understand preloading of bolts? BTL2 Understand
4. Explain the method of determining the size of the bolt when the bracket Remember
carries an eccentric load perpendicular to the axis of the bolt. BTL1

.
5. What do you understand by the single start and double start threads? BTL2 Understand

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6. Which type of thread would you suggest for the following?
a. Lead screw for a lathe Evaluate
b. Fastening of a bracket to a wall BTL5
c. Screw jack.
7.

8.
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Discuss on bolts of uniform strength giving examples of practical
application of such bolts.
List out the materials used for rivets.
BTL1

BTL1
Remember

Remember
9. What do you understand by the term efficiency of a riveted joint? BTL2 Understand
10. What do you understand by the term welded joint? BTL1 Remember
ad
11. What is the total shear in a double strap butt joint with equal length of Remember
straps? BTL1
12. What is an eccentric riveted joint? BTL4 Analyze
13. Classify the rivet heads according to Indian standard specifications. BTL6 Remembe
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14. What are the advantages of welded joints compared with riveted joints? BTL5 Evaluate
15. List out the different types of cotter joints? BTL1 Remember
16. Distinguish between cotter joint and knuckle joint. BTL2 Understand
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17. List out the various applications of a cottered joint. BTL1 Remember

18. Why gibs are used in a cotter joint? Explain BTL1 Remember
19. Name the possible modes of failure of riveted joint. Remember
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BTL1
20. What is a cotter joint? Explain with the help of a neat sketch, how a Remember
cotter joint is made? BTL1
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PART - B (13 Marks)

S.No QUESTIONS LEVEL COMPETENCE
A steam engine cylinder of 300mm effective diameter is subjected to a Apply
1 steam pressure of 1.5 MPa. The cylinder head is connected by means of 8
BTL3

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bolts having strength of 330 MPa. and endurance limit of 240 MPa. The
bolts are tightened with an initial preload of 1.5 times that of steam load.
A soft copper gasket is used to make the joint leak proof assuming a factor
of safety of 2; determine the size of the bolts required. The stiffness factor
for copper gasket may be taken as 0.5 (13)

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A mild steel cover plate is to be designed for an inspection hole in the

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shell of a pressure vessel. The hole is 120mm in diameter and the pressure
inside the vessel is 6N/mm2.Design the cover plate along with the bolts. Apply
2 BTL3
Assume allowable tensile stress for mild steel as 60 MPa and for bolt
material as 40 MPa. (13)

.
A bracket as shown in fig. supports a load of 30kN. Determine the size of

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bolts, if the maximum allowable tensile stress in the bolt material is 60
MPa. the distances are: L1 = 80 mm, L2 = 250 mm and L = 500mm (13)

3
ee BTL3
Apply
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For supporting the travelling crane in a workshop, the brackets are fixed
on steel columns as shown in fig. The maximum load that comes on the
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bracket is 12kN acting vertically at a distance of 400 mm from the face of

the column. The vertical face of the bracket is secured to a column by four
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bolts, in two rows (two in each row) at a distance of 50 mm from the

lower edge of the bracket; determine the size of the bolts if the permissible
value of the tensile stress for the bolt material is 84 MPa. Also find the Apply
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4 BTL3
cross-section of the arm of the bracket which is rectangular (13)
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A welded connection as shown in fig. below is subjected to an eccentric
force of 7.5KN. Determine the size of welds if the permissible shear stress
for the weld is 100 N/mm2. Assume static conditions. (13)

Apply
5 BTL3

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A 50mm diameter solid shaft is welded to a flat plate as shown in fig. if

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the size of the weld is 15 mm; Calculate the maximum normal and shear
stress in the weld. (13)
Apply
6 BTL3
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The structural connection shown in figure is subjected to an eccentric
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force P of 10 KN with an eccentricity of 500 mm from the CG of the
bolts. The centre distance between bolts 1 and 2 is 200 mm, and the centre
distance between bolts 1 and 3 is 150 mm. All the bolts are identical. The
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bolts are made plain carbon steel 30C8 (Syt = 400 N/mm2) and the factor
of safety is 2.5. Determine the size of the bolts. (13)

Evaluate
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7 BTL5
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Design a double riveted butt joint with two cover plates for the
longitudinal steam of a boiler shell 1.5 m in diameter subjected to a steam
pressure of 0.95 N/mm2. Assume joint efficiency as 75%, allowable Evaluate
8 BTL5
tensile stress in the plate 90MPa. compressive stress 14 MPa. and shear
stress in the rivet 56 MPa.

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A cylinder steam pressure vessel of 1 m inside diameter is subjected to an

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internal pressure of 2.5 MPa. Design a double-riveted, double-strap
longitudinal butt joint for the vessel. The straps are of equal width. The
pitch of the rivets in the outer row should be twice of the pitch in the inner
row. A zig-zag pattern is used for rivets in inner and outer rows. The

.
efficiency of the riveted joint should be at least 70%. The permissible

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tensile strength for the steel plate of pressure vessel is 80N/mm2. The Create
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permissible shear stress for the rivet material is 60 N/mm . Assume that
BTL6

the rivets in double shear and 1.875 times stronger than in single shear and
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the joint do nor fail by crushing. Calculate (i) Thickness of the plate (ii)
diameter of the rivets (iii) pitch of the rivets (iv) distance between inner
and outer rows of the rivets (v) margin (vi) thickness of the straps (vii)
efficiency of the joint. Make neat sketch showing all the calculated
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dimensions. (13)
Design a sleeve and cotter joint to resist a tensile load of 60 kN. All parts
of the joint are made of the same material with the following allowable Create
10 BTL6
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stresses: σt = 60 MPa; τ=70 MPa; and σc = 125 MPa. (13)

Design a cotter joint to connect piston rod to the crosshead of a double
acting steam engine. The diameter of the cylinder is 300mm and the steam
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pressure is 1N/mm2 . The allowable stresses for the material of cotter Create
11 BTL6
and piston rod are as follows. Tensile stress=50MPa, Shear Stresses=40
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MPa, Compressive stresses=84MPa. (13)

Design a knuckle joint for a tie rod of a circular cross section to sustain a
maximum pull of 70kN.The ultimate, strength of the material of the rod
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against tearing is 420 Mpa. The ultimate tensile and shearing strength of Evaluate
12 BTL5
the pin material are 510 MPa and 396 MPa respectively. Determine the tie
rod section and pin section. Take factor of safety=6. (13)

13 Design a knuckle joint to transmit 150 kN. The design stresses may be BTL6 Create

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taken as 75 MPa. in tension, 60 MPa in shear and 150 MPa in
compression. (13)
Design a gib and cotter joint to carry a maximum load of 35kN.Assuming
that the gib and cotter are of same material and have the following Create
14 BTL6
allowable stresses. σt = 20 MPa; τ=15 MPa; and σc = 50 MPa. (13)

t
PART-C (15 Marks)

ne
Specify the size and number of studs required to fasten the head of a 400
mm diameter cylinder containing steam at 2 N/mm2. A hard gasket Evaluate
1 (gasket constant =0.3) is used in making the joint. Draw a neat sketch of
BTL5

the joint also. Other data may be assumed.

.
pz
A steel plate is subjected to a force of 5KN and fixed to a channel by
means of 3 identical bolts as shown in figure. The bolts are made from
plain carbon steel for which yield stress in tension is 380 N/mm2 and
factor of safety is 3. Determine the size of the bolts.
ee
Evaluate
2 BTL5
ad
.p
w

Two mild steel rods 40mm diameter are to be connected by cotter joint.
w

The thickness of the cotter is 12mm. Calculate the dimensions of the joint, Create
3 if the maximum permissible stresses are 46 MPa; in tension 35MPa; in
BTL6

shear and 70 MPa in crushing.

w

Design a cotter joint to connect a piston rod to the crosshead. The

maximum steam pressure on the piston rod is 35 kN. Assuming that the all Create
4 parts are made of the same material having the following permissible
BTL6

stress: σ1= 50MPa; τ = 60 MPa; σ = 90 MPa.

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UNIT IV - ENERGY STORING ELEMENTS AND ENGINE PERMANENT JOINTS

Various types of springs, optimization of helical springs - rubber springs - Flywheels considering stresses in rims
and arms for engines and punching machines- Connecting Rods and crank shafts.
PART - A (2Marks)
S.No QUESTIONS LEVEL COMPETENCE
1. Describe the type of spring is used to maintain an effective contact

t
Understand
BTL2
between a cam and a reciprocating roller or flat faced follower?

ne
2. List out the various function of a spring. In which type of sprig the Remember
BTL1
behaviour is non-linear?
3. The extension springs are in considerably less use than the compression Evaluate
BTL5
springs. Why?

.
4. While designing helical springs K is introduced in the shear stress Remember
equation, why? BTL1

pz
5. What do you understand stiffness of spring? BTL2 Understand
6. Discuss any one method of avoiding the tendency of a compression spring Understand
to buckle. BTL2

7.

8.
spring?
ee
What do you understand by full length and graduated leaves of a leaf

What is nipping in a leaf spring?

BTL2

BTL2
Understand

Understand
9. Define surge in a spring. BTL1 Remember
10. Discuss the utility of the centre bolt, U- clamp, rebound clip and camber
ad
BTL2 Understand
in a leaf spring.
11. List out the main function of a flywheel in an engine? BTL1 Remember
12. In what way does a flywheel differ from that of a governor? BTL5 Evaluate
.p

13. Define coefficient of fluctuation of speed and coefficient of steadiness. BTL1 Remember
14. Discuss the various types of stresses induced in a flywheel rim. BTL2 Understand
15. Describe why flywheels are used in punching machines? BTL1 Remember
16. Define the term fluctuation of energy. BTL1 Remember
w

17. Explain why I-section is chosen for the connecting rod? BTL4 Analyze

18. Explain what are the stresses set up in an IC engine connecting rod? BTL4 Analyze
w

19. At what angle of the crank, the twisting moment is maximum in the Evaluate
crankshaft BTL5
20. List out the various methods and materials used in the manufacture of Remember
BTL1
w

crankshafts.

PART - B (13 Marks)

S.No QUESTIONS LEVEL COMPETENCE
Design a helical compression spring to sustain an axial load of 3KN. The Apply
1 deflection is 60mm. Spring index is 6. The shear stress is not to exceed
BTL3

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300 MPa. Rigidity modulus for spring material is 81 GPa.
A spring loaded safety value for a boiler is required to blow-off at a
pressure 1.2 N/mm2. The diameter of the value is 60 mm. Design a
suitable compression spring for the safety value, assuming spring index to Create
2 be 5, and 35 mm initial compression. The maximum lift of the valve is 10
BTL6

t
mm. The shear stress in the spring material is to be limited to 500 MPa.

ne
Take G = 0.8 x 105 MPa. (13)
A helical compression spring made of circular wire is subjected to an axial
force, which varies from 2.5KN to 3.5 KN. Over this range of force, the
deflection of the spring should be approximately 5mm. The spring index

.
can be taken as 5. The spring has square and ground ends. The spring is

pz
made of patented and cold-drawn steel wire and ultimate tensile strength
of 1050 N/mm2 and modulus of rigidity of 81370 N/mm2. The permissible Create
3 BTL6
shear stress for the spring wire should be taken as 50% of the ultimate
ee
tensile strength. Design the spring and calculate (i) Wire diameter (ii)
mean coil diameter (iii) number of active coils (iv) total number of coils
(v) solid length of spring (vi) free length of spring (vii) required spring
rate (viii) actual spring rate. (13)
ad
At the bottom of a mine shaft, a group of 10 identical close coiled helical
springs are set in parallel to absorb. The shock caused by the falling of the
cage in case of a failure. the loaded cage weighs 75KN, while the counter
.p

weight has a weight of 15KN. If the loaded cage falls through a height f Apply
4 50 meters from rest, find the maximum stress induced in each spring if it
BTL3

is made of 50mm diameter steel rod. The spring index is 6 and the number
w

of active turn in each spring is 20. Modulus of rigidity G= 80KN.mm 2 .

(13)
w

Design and draw a valve spring of a petrol engine for the following
operating conditions.
Spring load when the valve is open = 400 N
w

Spring load when the valve is closed = 250 N Create

5 BTL6
Maximum inside diameter of spring = 25mm
Length of the spring when the valve is open = 40mm
Length of the spring when the valve is closed = 50mm

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Maximum permissible shear stress = 400 MPa (13)
A concentric spring for an aircraft engine valve is to exert a maximum
force of 5000N under an axial deflection of 40mm.Both the springs have
same free length, same solid length and are subjected to equal maximum
shear stress of 850 MPa. If the spring index for both the spring is 6,find Create
6 BTL6

t
(a) the load shared by each spring,(b) the main dimensions of both the

ne
springs and (c) the number of active coils in each spring.
G=80kN/mm2and diametric clearance to be equal to the difference
between the wire diameter. (13)
Design a leaf spring for the following specifications: Total load = 140 kN

.
; Number of springs supporting the load = 4 ; Maximum number of leaves

pz
= 10; Span of the spring = 1000 mm ; Permissible deflection = 80 mm. Create
7 BTL6
Take Young’s modulus, E = 200 kN/mm2 and allowable stress in spring
material as 600 MPa. (13)
ee
A semi-elliptical laminated vehicle spring to carry a load of 6000N is to
consist of seven leaves 65mm wide, two of the leaves extending the full
length of the spring. The spring is to be 1.1m in length and attached to the
axle by two U-bolts 80mm apart. The bolts hold the central portion of the
ad
spring so rigidly that they may be considered equivalent to a band having Create
8 BTL6
a width equal to the distance between the bolts. Assume the design stress
for spring material as 350 MPa. Determine thickness of the leaves,
.p

deflection of spring, diameter of eye, length of leaves and radius to which

leaves should initially bent. (13)
A 5kW induction motor, running at 960 rpm operates a riveting machine.
w

The flywheel fitted to it, is of mass 120 kg, with radius of gyration equal
to 0.35 m. Each riveting takes 1 second and requires 9 kW. Determine (i) Apply
9 BTL3
w

the number of rivets formed per hour and (ii) the reduction in speed of the
flywheel, after the riveting operation. (13)
A single cylinder, single acting, four stroke oil engine develops 20kW at
w

300 rpm. The work done by the gases during the expansion stroke is 2.3
times the work done on the gases during the compression and the work Evaluate
10 BTL5
done during the suction and exhaust strokes is negligible. The speed is to
be maintained within ±1%.Determine the mass moment of inertia for the

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flywheel. (13)
The turning moment diagram for a petrol engine is drawn to the following
scales. Turning moment,1mm=5N.m,Cranking angle 1mm=1º.The turning
moment diagram repeats itself at every half revolution of the engine and
the areas above and below the mean turning moment line, taken in order

t
are 295,685,40,340,960,270mm2 .Determine the mass of 300 mm Apply
11 BTL3

ne
diameter flywheel rim when the co-efficient of fluctuation of speed is
0.3% and the engine runs at 1800 rpm. Also determine the cross section of
the rim when the width of the rim is twice of thickness. Assume density of
rim material as 7250kg/m3. (13)

.
Design a plain carbon steel centre crankshaft for a single acting four

pz
stroke single cylinder engine for the following data. Bore = 400mm;
Stroke = 600 mm; Engine speed = 200 rpm; Mean effective pressure = 0.5
N/mm2; Maximum combustion pressure = 2.5 N/mm2; Weight of flywheel

12
ee
used as a pulley = 50 KN; Total belt pull = 6.5 kN. When the crank has
turned through 35˚ from the top dead center, the pressure on the piston is
BTL3
Apply

1N/mm2 and the torque on the crank is maximum. The ratio of the
connecting rod length to the crank radius is 5. Assume any other data
ad
required for the design. (13)
The turning moment diagram of a multi-cylinder engine is drawn with a
scale of (1mm =1˚) on the abscissa and (1mm = 2N-m) on the ordinate.
.p

The intercepted area between the torque developed by the engine and the
mean resisting torque of the machines, taken in order from one end are
-350, +800, -600, +900, -550, +450 and -650 mm2. The engine is running
w

at a mean speed of 750 rpm and the coefficient of speed fluctuation is Create
13 BTL6
limited to 0.02. A rimmed flywheel made of gray cast iron FG200
w

(density=7100 Kg/mm3) is provided. The spokes, hub and shaft are

assumed to contribute 10% of the required moment of inertia. The rim has
rectangular cross-section and the ratio of width to thickness is 1.5.
w

Determine the dimensions of the rim. (13)

Design a connecting rod for an IC engine running at 1800 rpm and
developing a maximum pressure of of 3.15 N/mm2.The diameter of the Create
14 BTL6
piston is 100mm,mass of the reciprocating parts per cylinder

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2.25kg,length of connecting rod 380mm,stroke of piston190mm and
compression ratio 6:1.Take a factor of safety as 6 for the design. Take
length to diameter ratio for big end bearing as 1.3 and small end bearing
as 2 and the corresponding bearing pressures as 10N/mm2 and 15
N/mm2.The density of material of the rod may be taken as 8000kg/m3 and

t
the allowable stress in the bolts as 60N/mm2 and in cap as 80N/mm2.The

ne
rod is to be of I section for which you can choose your own proportions.
Use Rankine formula for which the numerator constant may be taken as
320 N/mm2 and the denominator constant 1/7500. (13)

PART-C (15 Marks)

.
It is desired to design a valve spring of I.C. engine for the following

pz
details: a) Spring load when valve is closed = 80N b) Spring load when
valve is open = 100 N c) Space constraints for the fitment of spring are:
inside guide bush diameter = 24mm Outside recess diameter = 36mm d)

1
ee
Valve lift =5mm e) Spring steel has the following properties Maximum
permissible shear stress = 350 MPa. Modulus of rigidity = 84kN/mm 2 BTL5
Evaluate

Find: 1. Wire diameter 2. Spring index 3. Total number of coils 4. Solid

length of springs 5. Free length of spring 6. Pitch of the coil when
ad
additional 15 percent of the working deflection is used to avoid complete
closing of coils.
A semi-elliptical laminated spring 900 mm long and 55 mm wide is held
.p

together at the centre by a band 50mm wide. If thickness of each leaf is

5mm, find the number of leaves required to carry a load of 4500 N. Evaluate
2 Assume a maximum working stress of 490 MPa. If the two of these leaves
BTL5
w

extend the full length of the spring, find the deflection of spring. The
young’s modulus for the spring material may be taken as 210 kN/mm2.
w

A punching press pierces 35 holes per minute in a plate using 10kN-m of

energy per hole during each revolution. Each piercing takes 40 per cent of
the time needed to make one revolution. The punch receives power
w

through a gear reduction unit which in turn is fed by a motor driven belt Create
3 BTL6
pulley 800 mm diameter and turning at 210 rpm. Find the power of the
electric motor if overall efficiency of the transmission unit is 80 per cent.
Design a cast iron flywheel to be used with the punching machine for a

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 www.padeepz.net
coefficient of steadiness of 5, if the space considerations limit the
maximum diameter to 1.3 m. Allowable shear stress in the shaft material =
50MPa; Allowable tensile stress of cast iron = 4 MPa. Density of cast iron
= 7200 kg/m3
Explain why the standard I-section is chosen for designing of connecting

t
rod over other cross section without sacrificing the fundamental and write Create
4 BTL6

ne
the design equation for connecting rod based on crippling load.

.
pz
ee
ad
.p
w
w
w

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UNIT V - BEARINGS
Sliding contact and rolling contact bearings - Hydrodynamic journal bearings, Sommerfeld Number, Raimondi and
Boyd graphs, -- Selection of Rolling Contact bearings.
PART - A (2Marks)
S.No QUESTIONS LEVEL COMPETENCE
1. Give two application where the inner race is rotating and out race is Understand
BTL2

t
stationary in rolling contact bearings.
2. Give an example for anti-friction bearing. Understand

ne
BTL2
3. List the advantages of hydrostatic bearings. BTL3 Apply
4. List any two advantages of rolling contact bearings. BTL1 Remember
5. In hydrodynamic bearing, what are factors which influence the formation of wedge Evaluate
BTL4

.
fluid film?
6. Define static capacity of bearing. BTL1 Remember

pz
What is full journal bearing? Give a classification of these bearings. BTL2 Understand
7.
8. Explain hydrodynamic lubrication. BTL5 Evaluate
9. List the important physical characteristics of a good bearing material. BTL1 Remember
10. Define bearing characteristic number.
ee BTL1 Remember
11. List out the application of angular contact and self-aligning ball bearings. BTL1 Remember
12. How do you express the life of a bearing? What is an average or median Understand
life? BTL2
13. Describe basic static load rating BTL1 Remember
ad
14. Describe bearing characteristic number. BTL2 Understand
15. Write down the formula to calculate the heat generated and heat dissipated in Create
BTL6
journal bearing.
16. Define critical pressure. BTL1 Remember
.p

17. Write down the formula to calculate sommerfield number. BTL6 Create

18. State the theory of lubrication. BTL5 Evaluate

19. What do you understand by non-metallic bearings? BTL2 Understand
w

20. Explain partial journal bearing. BTL5 Evaluate

PART - B (13 Marks)

w

S.No QUESTIONS LEVEL COMPETENCE

A full journal bearing of 50 mm diameter and 100 mm long has a bearing
pressure of 1.4 MPa. The speed of the journal is 900 rpm and the ratio of
w

journal diameter to the diametrical clearance is 1000. The bearing is Apply

1 lubricated with oil whose absolute viscosity at the operating temperature
BTL3

of 75˚C may be taken as 0.011 kg/m-s. The room temperature is 35˚C.

Calculate (i) The amount of artificial cooling required and (ii) The mass of

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the lubricating oil required, if the difference between the outlet and inlet
temperature of the oil is 10˚C. Take specific heat of the oil as
1850 J/kg/˚C. (13)
The load on the journal bearing is 150kN due to turbine shaft of 300mm
diameter running at 1800 rpm. Determine the following. Length of the

t
bearing if the allowable bearing pressure is 1.6N/mm2 and amount of heat Apply
2

ne
BTL3
to be removed by the lubricant per minute if the bearing temperature is
60ºC and viscosity of the oil at 60ºC is 0.02 kg/m.s and the bearing
clearance is 0.25 mm. (13)
Design a journal bearing for a centrifugal pump from the following data:

.
Load on the journal = 20000N; Speed of the journal = 900 rpm; Type of

pz
oil is SAE 10 for which the absolute viscosity at 55˚C = 0.017 kg/m-s;
Ambient temperature of oil = 15.5˚C; Maximum bearing pressure for the Create
3 BTL6
pump = 1.5 N/mm2. Calculate also mass of the lubricating oil required for
ee
artificial cooling, if rise of temperature of oil be limited to 10˚C. Heat
dissipation coefficient = 1232 W/m2/˚C (13)
A 100mm diameter full journal bearing supports a radial load of 5000N.
The bearings is 100 mm long and operates at 400 rpm. Permissible min
ad
film thickness 25 micron. Diametral clearance 152 micron using Raimond Apply
4 & Boyd curves find (i) viscosity of suitable oil (ii) µ (iii) heat generation
BTL3

rate (iv) amount of oil pumped through bearing (v) amount of end leakage
.p

(vi) rise in temperature (13)

The following data is given for full hydrodynamic bearing used for
electric motor radial load = 1200N; journal speed = 1440 rpm; journal
w

diameter = 50mm static load on the bearing = 350 N. The values of

surface roughness of the journal and bearing are 2 and 1 micron
Apply
w

5 respectively. The minimum oil film thickness be five times the sum of BTL3
surface roughness of the journal and the bearing. Determine (i) length of
the bearing (ii) radial clearance (iii) minimum oil film thickness (iv)
w

viscosity of lubricant (v) flow of lubricant select suitable oil for this
application assuming the operating temperature as 65˚C (13)

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A shaft rotating at constant speed is subjected to variable load. The
bearings supporting the shaft are subjected to stationary equivalent radial
load of 3kN for 10% of time, 2kN for 20% of time, 1kN for 30% of time Apply
6 and no load for remaining cycle time. If the total life expected for the
BTL3

bearing is 20x106 revolutions at 95% reliability, calculate dynamic load

t
rating of the ball bearing. (13)

ne
The rolling contact ball bearings are to be selected to support the
overhung countershaft. The shaft speed is 720 rpm. The bearings are to
have 99% reliability corresponding to a life of 24000 hours. The bearing is Evaluate
7 subjected to an equivalent radial load of 1kN.Consider life adjustment
BTL5

.
factors for operating condition and material as 0.9 and 0.85 respectively.

pz
Find the basic dynamic load rating of the bearing has 90% reliability.(13)
Select a single row deep groove ball bearing for a radial load of 4000N
and an axial load of 5000N, operating at a speed of 1600 rpm for an Apply
8
ee
average life of 5 year at 10hours per day. Assume uniform and steady
load. (13)
BTL3

The ball bearings are to be selected for an application in which the radial
load is 2000N during 90 percent of the time and 8000N during the
ad
remaining 10 percent. the shaft is to rotate at 150 rpm. Determine the Evaluate
9 BTL5
minimum value of the basic dynamic load rating for 5000 hours of
operation with not more than 10 percent failures. (13)
.p

A ball bearing subjected to a radial load of 4000 N is expected to have a

satisfactory life of 12 000 hours at 720 r.p.m. with a reliability of 95%.
Calculate the dynamic load carrying capacity of the bearing, so that it can Create
w

10 be selected from manufacturer's catalogue based on 90% reliability. If

BTL6

there are four such bearings each with a reliability of 95% in a system,
w

what is the reliability of the complete system? (13)

A single row deep groove ball bearing operating at 2000 rpm is acted by a
10 kN radial load and 8kN thrust load. The bearing is subjected to a tight
w

Evaluate
11 shock load and the outer ring is rotating. Determine the rating life of the
BTL5

bearing. (13)
A shaft transmitting 50KW at 1255 rpm from the gear G1 to the gear G2 Create
12 and mounted on two single-row deep groove ball bearings B1 and B2 as
BTL6

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shown. The gear tooth force are Pt1 = 15915 N; Pr2 - 5793 N; Pt2 = 9549 N
and Pr2 = 3476N. The diameter of the shaft at bearings B1 and B2 is 75
mm. The load factor is 1.4 and the expected life for 90% of the bearings is
10000h. Select suitable ball bearings.

t
. ne
pz
ee
A roller bearing is be selected to withstand a radial load of 4000N and
have an L10 life of 1200 hours at a speed of 600 rpm
i. What is the basic dynamic load rating of the bearing to be
Evaluate
13 selected? (8)
BTL5
ad
ii. If the reliability required is 99%, what load rating would be used?
Take b=1.17 and V=S=1 (5)
Select a single row deep groove ball bearing with the operating cycle as
.p

below which will have a life of 15000hours.Assume radial and axial load
factors to be 1 and 1.5 respectively and inner race rotates. (13)
Fraction Type of Radial, Thrust, Speed, Service
w

of cycle load N N RPM factor

1/10 Heavy 2000 1200 400 3
Evaluate
14 BTL5
w

shocks
1/10 Light 1500 1000 500 1.5
shocks
w

1/5 Moderate 1000 1500 600 2

shocks
3/5 No shocks 1200 2000 800 1

PART-C (15 Marks)

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A ball bearing operates on the following work cycle:

Element Radial Load

Speed (RPM) Element Time
No. (N)
1 3000 720 30
Create
1 2 7000 1440 40 BTL6

t
3 5000 900 30

ne
The dynamic load capacity of the bearing is 16 600 N. Calculate 1. The
average speed of rotation; 2. The equivalent radial load; and 3. The
bearing life.

.
A ball bearing subjected to a radial load of 5 kN is expected to have a life

pz
of 8000 hours at 1450 rpm with a reliability of 99%. Calculate the Create
2 dynamic load capacity of the bearing so that it can be selected from the
BTL6

manufacturers catalogue based on a reliability of 90%.

ee
Select appropriate type of rolling contact bearing under the following
condition of loading giving reasons for your choice:

a. Light radial load with high rotational speed.

Evaluate
ad
3 b. Heavy axial and radial load with shock BTL5

c. Light load where radial space is very limited

d. Axial thrust only with medium speed.

.p

A tentative design of a journal bearing results in a diameter of 75mm and

a length of 125mm for supporting a load of 20 kN. The shaft runts at 1000
w

rpm. The bearing surface temperature is not to exceed 75˚C in a room Evaluate
4 temperature 35˚C. The oil used has an absolute viscosity of 0.01 kg/m-s at
BTL5
w

the operating temperature. Determine the amount of artificial cooling

required in watts. Assume d/c=1000.
w

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