MACHINE DESIGN AND SHOP PRACTICES

PREPARED BY: ENGR. GILBERT M. MENDOZA, ECE, ME

FIC, ME DEPARTMENT

1. An Iron rod 5 m long and 0.8 square cm in cross section stretches 1 mm

when a mass of 250 kg is hanging on It. Compute the modulus of elasticity
of the iron.
2. A steel wire 12 m long, hanging vertically supports a tensile load of
3 kN. Neglecting the weight of wire, determine the required diameter If
the stress Is not to exceed 130 MPa and the total elongation is not to
exceed 6 mm. Let E=220 MPa.
3. Determine the minimum diameter of a taper pin for use to fix a lever to
a shaft, it is to transmit a maximum torque of 800 in-lb. The shaft
diameter Is 1.8-in and has a stress of 22,000 psi.
4. How many 1/2-ln diameter holes that can be punched in one motion of a
1/8-ln thick plate using a force of 80 tons. The ultimate shear stress
is 58 ksi and design factor of 5.
5. A shaft whose torque varies from 2000 to 6500 In-lb. It has a diameter
of 1.25-In and yield stress of 62000 psi. Find the variable stress
components.
6. If the ultimate shear strength of steel plate Is 46,000 psi, what force
is necessary to punch a 1.0-in diameter hole in a 3/4-ln thick plate,
use a factor of safety of 3.0.
7. The Internal pressure of a 380 mm Inside diameter cylindrical tank is
12 MPa and thickness is 28 mm. Compute the stress developed if joint
efficiency Is 85%.
8. Compute the safe wall thickness of a 60-In steel tank with an Internal
pressure of 10 MPa. The ultimate stress Is 300 MPa and the factor of
safety Is 3.
9. A water tank Is 12 m x 15 m Is filled with water. Find the minimum
thickness of the plate If stress is limited to 60 MPa
10. Determine the bursting steam pressure of a steel shell with
diameter of 18-in and made of %-ln steel plate. The joint efficiency is
90% and the tensile strength Is 65000 psi.
11. Find the Internal pressure or a cylindrical tank 600 mm Internal
diameter, 23 mm thick and 3.5 m length If stress limited to 150 MPa.
12. A spring has a spring rate of 40 kN/m. If the wire diameter Is 12
mm with a mean diameter of 80 mm, find the number of active coils. Let
G=85 GN/m2.
13. A spring with plain ends has 16 active coils with wire diameter of
7 mm and pitch of 12 mm. If the spring rate is 90 kN/m, find the solid
force.
14. A squared and ground ends spring has a pitch of 18 mm, wire diameter
of 12.4 mm. If there are 14 actual number of coils, the deflection of
the spring when compressed to its solid length is.
15. A leaf spring is made of 4-in wide with effective length of 15-in
and thickness of 0.20-In. The spring has three full- length and six
graduated leaves. If the central load carried is 1200 lb., find the
deflection.
16. A leaf spring is made of 3.5-in wide with effective length of 18-
in and thickness of 0.3-in. The spring has two full-length and five
graduated leaves. If the central load carried is 600 lbs, find the
maximum stress for the leaves.
17. A rectangular key is used in a pulley connection to transmit 120
kW at 1300 rpm on a 55-mm shaft diameter. Determine the force required
to remove the shaft from the hub if f=0.50.
18. An 80 mm diameter shafting of SAE 1040 grade, cold rolled, having
a yield point of 55 ksi and 1/2 x 3/4 x 4 inches key. Compute the
minimum yield point in the key in order to transmit the torque of the
shaft. The factor of safety Is 5.
19. A flat key is to be designed for 75 mm diameter shaft which will
transmit a 200-kW power at 420 rpm. If the allowable shearing stress^
is 220 MPa and the key width is 18 mm, find the length of the key.
20. A 6-spline shaft (d=0.80D, b=0.25D, t=0.10D) to slide when under
load has a compressive area of 2.5 in2 and shearing area of 3.5 in2.
Find the minimum diameter of the shaft required If the hub length Is
2.25-in.
21. A 1-1/2-in diameter, 4-spline shaft (d = 0.85D, b = 0.241D,
t=0.075D) and permanent fit, has a permissible pressure of 900 psi.
Find the shearing force in the spline, if the hub length Is 2-in.
22. The root diameter of a double square thread power screw is 0.60-
In. The screw has a pitch of 0.3-In. Determine the major diameter.
23. A double square thread power screw has a mean radius of 90 mm and
pitch of 12 mm is used to lift a load of 90 kN. If the friction of screw
Is 0.14 and collar torque Is 25% of Input torque, find the Input torque
required.
24. An Acme thread power screw that has a mean diameter of 28 mm and
pitch of 6 mm is used to lift a load of 800 kg. If the friction on
thread Is 0.95, compute the torque needed to turn the screw.
25. A single square thread power screw has a lead of 7 mm and mean
diameter of 35 mm. If it Is used to lift a load of 30 kN and coefficient
of friction of thread Is 0.18, find the torque required to turn the
screw.
26. The total torque required to turn the power screw is 55 N- m. If
the linear speed of screw is 8 ft/min and lead of 9 mm, determine the
horsepower input of the power screw.
27. Find the angle of contact on the small pulley for a belt drive
with center distance of 75-in. If pulley diameters are 9-in and 18-in,
respectively.
28. A nylon-core flat belt has an elastomer envelop 200 mm wide and
transmits 70 kW at a belt speed of 30 m/s. The belt Is used in a crossed
configuration to connect a 280 mm diameter driving pulley to a 910 mm
diameter driven pulley at a shaft spacing of 5 m. Calculate the belt
length and the angles of wrap.
29. Compute the belt tensions based on a coefficient of friction of
0.35.
30. A driving sprocket with 12 teeth drives another sprocket with 48
teeth by means of a chain having a pitch of 3/4-ln. If chain length is
75-In, find the center distance between sprockets.
31. A sprocket with 9.0-in diameter and pitch of 3/4-in drives another
sprocket at standard center distance of 50 pitches. Find the diameter
of larger sprocket.
32. A 20 teeth sprocket driving an ICO teeth sprocket a center distance
of 38 pitches. Find the chain length, In pitches.
33. A chain and sprocket have a pitch diameter of 30-In and with 90
teeth available. Find the pitch of the chain.
34. A chain and sprocket have a pitch diameter of 9.56-ln and pitch of
1/2-ln. How many teeth are there in the sprocket?
35. A chain and sprocket have 24 teeth with chain pitch of 3/4- In. If
the sprocket turns 620 rpm, find the speed of the chain.
36. A flange coupling with bolt circle diameter of 260 mm uses 8 bolts,
25 mm diameter. The torque transmitted is 18 kN-m and compressive stress
of bolt is 18 MPa. Calculate the required flange thickness.
37. The total force of 130 kN Is required for the flange coupling that
has 6 bolts and a shearing stress of 38 MPa for the bolt. Compute the
required bolt diameter.
38. A turbine is connected to a generator by means of a flange coupling
that has a bolt circle diameter of 520 mm. The generator output Is 50
MW, 3600 rpm and 85% efficiency. If there are 18 bolts, determine the
force acting on each bolt.
39. Determine the power capacity of uniform wear cone clutch having a
major diameter of 280 mm, minor diameter of 210 mm, length of contact
of 120 mm, f =0.28, speed of 850 rpm and has an operating force of 600
N.
40. Find the cone angle of a clutch having a major diameter of 280 mm
and minor diameter of 220 mm and length of contact of 260 mm.
41. Find the power capacity and the cone angle of a cone clutch under
uniform pressure having 220 mm major diameter, 180 mm minor diameter,
length of contact of 120 mm, 880 rpm, f=0.35, and allowable pressure of
80 kPa.
42. A steel band has a maximum tensile stress of 60 MPa and thickness
of 5 mm. If the tension in the tight side Is 8 kN, what width of band
should be used?
43. On a brake drum the difference in tension between the slack side
and the tight side is 8 kN. If the ratio in the band tension is 4,
determine the tension in the tight side.
44. In a brake, the tension on tight side is thrice the slack side. If
coefficient of friction is 0.30, determine the angle of contact of the
band.
45. A brake has a difference in band tension of 5 kN. The drum diameter
is 1.5 meter and rotating at 280 rpm. Calculate the power needed to
drive the drum.
46. An 800 kg flywheel changes Its speed from 200 rpm to 170 rpm during
punching. If the mean diameter of the flywheel is 650 mm, find the
energy released by the flywheel.
47. Find the pressure needed to punch a 3.5-In diameter hole from a
1.5-ln thick steel plate.
48. A 5.50 ft mean diameter flywheel has to absorb 3800 ft-lb of energy
and maintain a coefficient of fluctuation of 0.10. If the mean speed is
90 ft/sec, find the weight of the flywheel.
49. A flywheel weighing 1200 kg has a radius of gyration of 1.80 m.
The normal operation speed Is 180 rpm and coefficient of fluctuation of
0.08. Find the kinetic energy released by the flywheel.
50. A 50-in diameter flywheel has a weight of 830 lbs. During
operation, the speed is 190 rpm. If the coefficient of fluctuation is
0.88, calculate the energy released by the flywheel.
51. A standard 20 deg full-depth spur gear has 26 teeth and circular
pitch of 0.785-in. Compute the working depth.
52. How many revolutions per minute Is a spur gear turning if It has
a module of 3 mm, 42 teeth, and pitch line velocity of 2600 mrn/sec?
53. How many revolutions per minute Is a spur gear turning, If It has
30 teeth, a circular pitch of 0.785-in and a pitch line velocity of 15
ft/sec?
54. What is the pitch diameter of a 42 teeth spur gear having a circular
pitch of 1.60?
55. A spur gear 20 deg full-depth involute teeth has an outside
diameter of 190 mm and module of 5.2778. Find the number of teeth.
56. A triple thread worm gear having a diametral pitch of 5-ln is used
to deliver a gear. The speed ratio is 8. Find the pitch line velocity
of gear if the worm rotates at 650 rpm.
57. A double thread worm has a helix angle of 83 deg and pitch diameter
of 5.75-in. The worm rotates at 820 rpm. Find the linear speed of the
worm.
58. A triple thread worm gear is used to drive a 24 teeth gear having
a pitch of 0.75-In. Compute the center distance.
59. A double thread worm having a pitch of 1-in Is used to drive a 42
teeth gear. Find the pitch diameter of the gear.
60. A triple-thread worm, rotating at 1,200 rpm, drives 32- teeth gear.
Find the speed of the gear.
61. In an Oxygen-acetylene manual welding, to weld a 6-ft long seam in
a 3/4-in thick steel plate at a consumption rate of 12 ft3/ft for oxygen
and 10 ft3/ft for acetylene. Find the total gas consumption, In ft3.
62. Compute the drill penetration In Inch per minute when a drill turns
at 1200 rpm and the feed of 0.005-In per revolution.
63. Find the time, in seconds, to saw a rectangular bar 8-In wide and
1.8-in thick if the length of cut is 8-In, the power hacksaw does 130
strokes per minute and the feed per stroke is 0.155 mm.
64. Compute the cutting speed, fpm of a work piece with 6-In diameter
and running at 120 rpm.
65. Calculate the manual cutting time in minutes of a steel plate 4
ft x 8 ft by V^-in thick with a hand cutting speed of 4 to 5 mm/sec,
cutting crosswise.
66. At a given section of an I beam the maximum bending stress
occurs at the
a. Maximum shear stress area
b. Neutral axis
c. Web joint near the flange
d. Outermost
67. The resultant of two or more forces is a
a. Couple of forcer
b. Concurrent of forces
c. Momentum
d. Resolution of forces
68. Two or more forces acting together, could be replaced by a
single force with same effect in a mass called:
a. Couple of forces
b. Resolution of forces
c. Resultant
d. Concurrent of forces
69. The frictional forces depends on coefficient of friction and
a. Torque
b. Weights of object
c. Normal of force
d. Moment
70. Shear modulus is also known as:
a. Shear elasticity
b. Poisson’s ratio
c. Modulus of elasticity
d. Modulus of rigidity
71. A key with one of several patented methods of keying is driven
or pressed into a hole that is small enough to close the slit,
assemble in radial direction.
a. Fit key
b. Saddle key
c. Roll pin
d. Pin key
72. Kennedy keys are also known as
a. Tangential keys
b. Normal keys
c. Saddle keys
d. Roll pin
73. A key that allows the hub to move along the shaft but prevents
the rotation of the shaft.
a. Woodruff key
b. Feather key
c. Gibbs key
d. Square key
74. Which of the following type of fits used for involutes spline?
a. Close fit
b. Press fit
c. Sliding fit
d. All of these
75. Used for permanent fits and are similar to involute splines
except the pressure angle is 14.5 deg.
a. Separation load
b. Stub serrations
c. Spline shaft
d. Involute serrations
76. A ________ is a kind of thread in which the width of the thread
and space between threads are approximately equal
a. Square thread
b. Acme thread
 c. Buttress thread
d. Whit worth thread
77. A kind of thread that is generally used
a. UNEC
b. UNC
c. UNF
d. UNEF
78. A type of bolt commonly used in the construction that is
threaded in both ends
a. Stud bolt
b. Acme threaded bolt
c. Square threaded bolt
d. Hex bolt
79. A hand tool used to measure tension in bolts
a. Shaver
b. Tachometer
c. Tensor
d. Torque wrench
80. One of the following is not a tap used for cutting threads in
holes
a. Tapping tap
b. Plug tap
c. Taper tap
d. Bottoming tap
81. Joining metal by means of high current at low voltage. During
the passage of current, pressure by the electrodes produces a forge
weld.
a. Spot welding
b. Resistance welding
c. Steam welding
d. Gas welding
82. A fusion process in which the metal is heated together into a
solid joint.
a. Electric arc welding
b. Gas welding
c. Spot welding
d. Projection welding
83. As one example, the ASME code for riveted joints permits the
design surface compressive stress to be about higher than
the design tensile stress.
a. 40%
b. 50%
c. 60%
d. 70%
84. In a pressure vessel, the ratio of minimum strength of joint to
the strength of solid joint is known as
a. Efficiency
b. Joint efficiency
c. Performance factor
d. Relative strength
85. In a pressure vessel, the usual factor of safety may be taken as
a. 2
b. 3
c. 4
d. 5
86. Soft solder is made of
a. Copper and zinc
b. Tin and copper
c. Tin and lead
d. Tin and zinc
87. Prepared soldered paste flux is most popular but if you did not
have any, you could use _____ as substitute.
a. Hydrochloric acid
 b. Nitric acid
c. Sulfuric acid
d. Any of the above
88. Hard solder is made of
a. Copper and zinc
b. Tin and copper
c. Tin and lead
d. Tin and zinc
89. Soldered will not unit with a metal surface that has
a. Dirt on it
b. Grease on it
c. Oxidation on it
d. Any of the above
90. If muriatic acid is used as a flux, the soldered area must be
cleaned thoroughly afterwards to prevent
a. Anyone touching it from getting burned
b. Remaining acid from eating the metal
c. The acid from evaporating and the solder disintegrating
d. None of the above