ME403 DESIGN OF MACHINE ELEMENTS 1 S7 ME

4. ME401 DESIGN OF MACHINE ELEMENTS 1

4.1 COURSE INFORMATION SHEET

PROGRAMME:MECHANICAL DEGREE: BTECH

ENGINEERING
PROGRAMME: MECHANICAL DEGREE: B.TECH
ENGINEERING University: APJ Abdul Kalam Technological
University
COURSE: DESIGN OF MACHINE
SEMESTER: VII CREDITS: 4
ELEMENTS 1
COURSE CODE: ME 401
COURSE TYPE: CORE
REGULATION: 2016
COURSE AREA/DOMAIN: MECHANICAL CONTACT HOURS: 3 hours lecture and 1
SYSTEMS, DESIGN AND ANALYSIS hour tutorial, per week

SYLLABUS:

MODULE CONTENTS HOURS

Introduction to Design- Definition, steps in design process,

preferred numbers, standards and codes in design.
I Materials and their properties- Elastic and plastic behavior of 9
metals, ductile and brittle behaviour, shear, bending and torsional
stresses, combined stresses, stress concentration factor.
Theories of Failure- Guest’s Theory, Rankine’s Theory, St. Venant’s
Theory, Haigh’s Theory, and Von Mises and Hencky Theory.
II 11
Shock and impact loads, fatigue loading, endurance limit stress,
factors affecting endurance limit, factor of safety.
Threaded Joints- Terminology, thread standards, types of threads,
stresses in screw threads.
III 7
Bolted joints- effect of initial tension, eccentric loading, design of
bolts for static and fatigue loading, gasketed joints, power screws
Design of riveted joints- Material for rivets, modes of failure,
efficiency of joint, design of boiler and tank joints, structural joints.
IV Cotter and Knuckle joints- Gib and Cotter Joint, analysis of knuckle 12
joint.
Design of welded joints- welding symbols, stresses in fillet and butt

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welds, Butt joint in tension, fillet weld in tension, fillet joint under
torsion, fillet wed under bending, eccentrically loaded welds.
Springs- classification, spring materials, stresses and deflection of
helical springs, axial loading, curvature effect, resilience, static and
fatigue loading, surging, critical frequency, concentric springs, end
V construction. 9

Leaf springs- Flat springs, semi elliptical laminated leaf springs,

design of leaf springs, nipping
Shafting- material, design considerations, causes of failure in shafts,
design based on strength, rigidity and critical speed, design for
static and fatigue loads, repeated loading, reversed bending.
VI 8
Design of Coupling- selection, classification, rigid and flexible
coupling, design of keys and pins.

TOTAL HOURS= 56

TEXT/REFERENCE BOOKS:

T/R BOOK TITLE/AUTHOR/PUBLICATION

T1 Machine Design Data hand book by K. Lingaiah, Suma Publishers, Bangalore/ Tata
Mc Graw Hill
T2 PSG Design Data, DPV Printers, Coimbatore.
T3 K. Mahadevan, K.Balaveera Reddy, Design Data Hand Book, CBS Publishers &
Distributors, 2013
T4 V.B. Bhandari, Design of Machine Elements, McGraw Hill Book Company
T5 R. L. Norton, Machine Design – An Integrated Approach, Pearson Education, 2001
T6 Jalaludeen , Machine Design, Anuradha Publications, Chennai,2014
R1 J. E. Shigley, Mechanical Engineering Design, McGraw Hill,2003
R2 Juvinall R.C & Marshek K.M., Fundamentals of Machine Component Design, John
Wiley,2003
R3 M. F. Spotts, T. E. Shoup, Design of Machine Elements, Pearson Education, 2006

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COURSE PRE-REQUISITES:
C.CODE COURSE NAME DESCRIPTION SEM
To understand the stresses and strains in
ME 201 Mechanics of Solids different materials and analyze strength 3
characteristic of structural members.

COURSE OBJECTIVES:
1 To review concepts of statics and strength of materials

2 To introduce fundamental approaches to failure prevention of components.

To provide knowledge in the design of common machine elements such as fasteners,
3 shafts, springs cotter joints and couplings

COURSE OUTCOMES:
Blooms’
Sl. NO DESCRIPTION
Taxomomy Level
Students will able to understand and identify the different
CME401.1 procedures to be followed during different phases of design Understand (Level 2)
process and understand the basic material properties.

Students will understand different failure theories and basic

CME401.2 Understand (Level 2)
concepts of deign factors like stress, factor of safety, etc.

Students will understand the basics of threaded and bolted Understand (Level 2)
joints. They will identify the forces acting on the joint and
calculate the maximum stress in the system. They will be Apply (Level 3)
able to compare and evaluate the permissible stress on a Analyze (Level 4)
CME401.3
material and select the material for required force. With the
optimum constrains students are able to design threaded and Evaluate (Level 5)
bolts. Create (Level 6)

Students will understand the basics and applications of Understand (Level 2)

riveted, cotter, kuckle, gib and welded joints. They will be
able to calculate and analyze the load on the system. Apply (Level 3)
According to the application, student will be able to choose Analyze (Level 4)
CME401.4
the type of joint and design the system to satisfy the
requirement. Evaluate (Level 5)
Create (Level 6)

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Students will be able to classify different type of springs. Understand (Level 2)

They will be able to predict different effects on the spring
Apply (Level 3)
under different loading conditions. According to application
CME401.5 they will be able to calculate the load and analyze the Analyze (Level 4)
deformation of the spring. By evaluating the load carrying
Evaluate (Level 5)
capacity, the student can design the spring to the required
system. Create (Level 6)

Understand (Level
Students will be able to explain the different design
2)
consideration while designing shaft and couplings. They
will be able to calculate the forces acting on the system. Apply (Level 3)
CME401.6 Students will be able to analyze and choose suitable Analyze (Level 4)
design parameters for the system. They will be able to
design couplings (shaft, keys, pins etc.) for the specified Evaluate (Level 5)
requirement.
Create (Level 6)

CO-PO AND CO-PSO MAPPING

PO PO PO PO PO PO PO PO PO PO PO PO PSO PSO PSO
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3
CME401.1 3 1 - - - - - - - - - - - - -

CME401.2 3 1 - - - - - - - - - - - - -

CME401.3 2 3 3 - - 3 - - - 3 - 2 - 3 -

CME401.4 2 3 3 - - 3 - - - 3 - 2 - 3 -

CME401.5 2 3 3 - - 3 - - - 3 - 2 - 3 -

CME401.6 2 3 3 - - 3 - - - 3 - 2 - 3 -
2. 2.
CME401 3 - - 3 - - - 3 - 2 - 3 -
33 33
1- Low correlation (Low), 2- Medium correlation(Medium) , 3-High correlation(High)

JUSTIFICATIONS FOR CO-PO MAPPING

LOW/MEDIUM/
MAPPING JUSTIFICATION
HIGH
CME401.1-PO1 H Students can gain the basic knowledge of steps involved in design process

CME401.1-PO2 L Students understands basic design procedure and material properties

CME401.2-PO1 H Students understand fundamental design factors and learn different failure

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theories.
Students are able to identify and formulate basic design factors like stress
CME401.2-PO2 L
and factor of safety.
CME401.3-PO1 M Student understands the basic concepts of threaded and bolted joints.
The forces acting of the system are identified. Formulations are solved to
CME401.3-PO2 H
select suitable parameter for design.

CME401.3-PO3 H With the optimum constrains threaded and bolts are designed.

CME401.3-PO6 H The design assures safety.

CME401.3-PO10 The documentation of design procedure is done so as to communicate the

H
information to required person.
With the advancement of technology, design concepts have to be improvised
CME401.3-PO12 M
to provide solution to the latest technology.
Student understands the basic concepts of riveted, cotter, knuckle, gib and
CME401.4-PO1 M
welded joints.
The forces acting of the system are identified. Formulations are solved to
CME401.4-PO2 H
select suitable parameter for design.
CME401.4-PO3 H With the optimum constrains riveted and welded joints are designed.
CME401.4-PO6 H The design assures safety.

CME401.4-PO10 The documentation of design procedure is done so as to communicate the

H
information to required person.
With the advancement of technology, design concepts have to be improvised
CME401.4-PO12 M
to provide solution to the latest technology.
CME401.5-PO1 M Student understands the basic concepts of springs
The forces acting of the system are identified. Formulations are solved to
CME401.5-PO2 H
select suitable parameter for design.
CME401.5-PO3 H With the optimum constrains springs are designed.
CME401.5-PO6 H The design assures safety.

CME401.5-PO10 The documentation of design procedure is done so as to communicate the

H
information to required person.
With the advancement of technology, design concepts have to be improvised
CME401.5-PO12 M
to provide solution to the latest technology.
CME401.6-PO1 M Student understands the basic concepts of shafts and couplings
The forces acting of the system are identified. Formulations are solved to
CME401.6-PO2 H
select suitable parameter for design.
CME401.6-PO3 H With the optimum constrains couplings (shaft, key, pins, etc.) are designed.
CME401.6-PO6 H The design assures safety.

CME401.6-PO10 The documentation of design procedure is done so as to communicate the

H
information to required person.
With the advancement of technology, design concepts have to be improvised
CME401.6-PO12 M
to provide solution to the latest technology.

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JUSTIFATIONS FOR CO-PSO MAPPING

MAPPING LOW/MEDIUM/HIGH JUSTIFICATION

Applying the principles of design for manufacturing threaded and

CME401.3-PSO2 H
bolted joints.
Applying the principles of design for manufacturing riveted and
CME401.4-PSO2 H
welded joints.
CME401.5-PSO2 H Applying the principles of design for manufacturing springs.
CME401.6-PSO2 H Applying the principles of design for manufacturing couplings

GAPS IN THE SYLLABUS - TO MEET INDUSTRY/PROFESSIONAL REQUIREMENTS:

SI PROPOSED RELEVANCE RELEVANCE
DESCRIPTION
NO ACTIONS WITH POs WITH PSOs
Belt drive and its Power Lecture 1,3
1 1
Transmission

TOPICS BEYOND SYLLABUS/ADVANCED TOPICS/DESIGN:

SI PROPOSED RELEVANCE RELEVANCE
DESCRIPTION
NO ACTIONS WITH POs WITH PSOs

1 Use of Finite Element in Projects/ 1,2,3,4,5 2,3

Design of Machine Elements Assignments

WEB SOURCE REFERENCES:

1 http://nptel.ac.in/downloads/112105125/
http://nptel.ac.in/courses/Webcourse-
2 contents/IIT%20Kharagpur/Machine%20design1/New_index1.html
http://www.iannauniversity.com/2012/06/me2303-design-of-machine-
3 elements_26.html

4 http://www.svecw.edu.in/Docs%5CMEDMMLnotes2013.pdf

DELIVERY/INSTRUCTIONAL METHODOLOGIES:
☑ CHALK & TALK ☑ STUD. ASSIGNMENT ☑WEB RESOURCES
☑ LCD/SMART
☐ STUD. SEMINARS ☐ ADD-ON COURSES
BOARDS

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ASSESSMENT METHODOLOGIES-DIRECT
☑ TESTS/MODEL ☑ UNIV.
☑ ASSIGNMENTS ☐ STUD. SEMINARS
EXAMS EXAMINATION
☐STUD. LAB ☐MINI/MAJOR
☐ STUD. VIVA ☐ CERTIFICATIONS
PRACTICES PROJECTS
☐ ADD-ON
☐ OTHERS
COURSES

ASSESSMENT METHODOLOGIES-INDIRECT
☑ASSESSMENT OF COURSE OUTCOMES (BY ☑ STUDENT FEEDBACK ON FACULTY
FEEDBACK, ONCE) (ONCE)
☐ ASSESSMENT OF MINI/MAJOR PROJECTS
☐ OTHERS
BY EXT. EXPERTS

4.2 COURSE PLAN

Day Module Topic

1 Introduction to Design- Definition

2 Steps in design process, preferred numbers
3 Standards and codes in design
4 Materials and their properties- Elastic behavior of metals
5 1 Materials and their properties- plastic behavior of metals
6 Ductile and brittle behavior, shear,
7 Bending and torsional stresses
8 Combined stresses
9 Stress concentration factor.
10 Theories of failure - Guest’s theory
11 Rankine’s theory -
12 St. Venant’s theory
13 2 Haigh’s theory
14 Von Mises & Hencky theory
15 Shock and impact loads
16 Fatigue loading

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17 Eendurance limit stress

18 Factors affecting endurance limit
19 Factor of safety
20 Creep and thermal stresses
21 Threaded Joints- Terminology
22 Thread standards- thread nomenclature
23 Stresses in screw threads
24 3 Bolted joints- effect of initial tension, eccentric loading
25 Design of bolts for static and fatigue loading
26 Gasketed joints
27 Power screws
28 Design of riveted joints –Materials for rivet
29 Failure of riveted joints and efficiency of joint
30 Boiler and tank joints structural joints
31 Cotter and Knuckle joints
32 Gib and Cotter Joint
33 Analysis of knuckle joint.
4
34 Design of welded joints- welding symbols
35 Stresses in fillet and butt welds
36 Butt joint in tension
37 Fillet weld in tension, fillet joint under torsion,
38 Fillet wed under bending,
39 Eccentrically loaded welds.
40 Springs- classification
41 Spring materials, stresses and deflection of helical springs,
42 Axial loading, curvature effect
43 Resilience, static and fatigue loading
44 5 Surging, critical frequency
45 Concentric springs, end construction.
46 Leaf springs- Flat springs
47 Semi elliptical laminated leaf springs
48 Design of leaf springs, nipping

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49 Shafting- material
50 Design considerations, causes of failure in shafts.
Design based on strength, rigidity and critical speed (Belt
51
Drives)
52 Design for static and fatigue loads
6
53 Repeated loading, reversed bending
54 Design of Coupling- selection, classification
55 Rigid and flexible coupling
56 Design of keys and pins

4.3 Sample questions

Module 1

1. Explain in detail the design consideration in design of machine elements

2. Briefly describe a) theories of failure b) Creep

3. Discuss the various factors affecting which govern the selection of material for machine
component.

4. Explain the weighted point method for material selection and state its limitations.

5. What are the ergonomic conditions in machine design?

6. Explain Fits and tolerances

7. Briefly describe standards and code in design.

8. Explain the term a) modulus of elasticity b) Explain ductile and brittle material using a
stress-strain diagram.

9. Explain a) combine stress b) stress concentration factor

10. Briefly explain the steps in design process

Module 2

1. Write a note on (i) fatigue failure and its prediction (ii) Factors affecting endurance limit.

2. A cantilever beam shown in figure below is subjected to load varying from P to 3P.
Determine the value of P if the material of beam has ultimate strength of 620.8 MPa., yield
strength of 400 MPa and endurance strength of 345.2 MPa. The stress concentration factor

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may be taken as 1.4. Analyze the member at the change of cross section A-A. Use factor of
safety =3.

3. A mild steel shaft of 50 mm diameter is subjected to a bending moment of 2000Nm and a

torque T. If the yield point of the steel in tension is 200 MPa., find the maximum principle
stress; the maximum shear stress of yielding.

4. A cylinder shaft made of steel of yield strength 700Mpa is subjected to static loads
consisting of bending moment 10kNm and a torsional moment 30 kNm. Determine the
diameter of the shaft using maximum shear stress theory and maximum strain energy
theory, assuming a factor of safety of 2. Take E=210 GPa and Poisson’s ratio = 0.25.

5. Explain the following theories of failure a) Maximum normal stress theory, b) Maximum
shear stress theory and c) Distortion theory

6. A rod of 50mm diameter is subjected to compressive load of 20 kN together with a

twisting moment of 1.5kNm. It is made of C40 steel (σyt = 328.6 MPa). Determine the factor
of safety according to a) maximum normal stress theory and b) Maximum shear stress
theory.

7. A bolt is subjected to tensile load of 18kN and a shear load of 12 kN. The material has a
yield stress of 328.6 MPa. Taking factor of safety as 2.5, determine the core diameter of bolt
according to the following theories of failure a) Rankine’s theory, b)Shear stress theory,
c)Shear energy theory and c) Saint Venant’s theory (Possion ratio = 0.298).

8. A machine member is subjected to the following stress σ x = 150 MPa, τ=24 MPa. Find
the equivalent stress as per the following theories of failure, a) Shear stress theory, b)
Normal stress theory and c) Von-Mises theory.

9. Find the diameter of a rod subjected to a bending moment of 3 kNm and a twisting
moment of 1.8 kNm according to the following theories of failure, taking normal yield
stress as 420 MPa and factor of safety as 3. a) Normal stress theory and b) Shear stress
theory.

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10. A M.S shaft having yield stress as 232 MPa is subjected to the following stresses σ x
=120 MPa and σ y =-60 MPa and τ = 36 MPa. Find the factor of safety using: a) Rankine’s
theory, b) Guest’s theory of failure and c) Von-Mises theory of failure.

Module 3

1. What are the different forms thread used for power screw? Explain with neat sketch.

2. A double threaded power screw, used for lifting the load, has nominal diameter of 30 mm
and a pitch of 6mm. The coefficient of friction in at the screw thread is 0.1. Neglecting collar
friction, calculate (a) Efficiency of the screw with square thread and (b) Efficiency with
Acme threads.

3. Distinguish between Differential and compound screw

4. A 50kN capacity screw jack consists of a square threaded steel screw meshing with a
bronze nut. The nominal diameter is 60mm and the pitch is 9mm. The permissible bearing
pressure at the thread is Is= 30N/mm2 Calculate: (a) The length of thread (b) The
transverse shear stress in the nut.

5. A sluice gate weighting 500kN is raised at a speed of 6 m/min by two screw rods with
square threads 50*8 mm. The two screw rods are driven by bevel gears and motor.
Determine (a) torque require to raise the gate; (b) speed of rotation of the screw rods
assuming the thread are triple start; (c) maximum stress induced in the screw; (d)
efficiency of the screw; (e) Length of nuts required to support to load taking the allowable
bearing pressure 12MPa; (f) check for overhaul

6. A square thread of screw jack has a specification of 80*16 and is to raise a load of 100kN.
The mean radius of the thrust collar is 65mm. The coefficient of friction for the thread and
collar are 0.1 and 0.12 respectively. Determine a) the torque required to raise the thread,
b) overall efficiency c) Does the screw overhaul. Comment.

7. The load on a bolt consists of an axial pull of 10 kN together with a transverse shear force
of 5 kN. Find the diameter of bolt required according to all the five theories of failure.

8. The cylinder head of a steam engine is subjected to a stream pressure of 0.7 N/mm2 . It is
held in position by means of 12 bolts. A soft copper gasket is used to make the joint leak
proof. The effective diameter of the cylinder is 300 mm. Find the size of the bolt so that the
stress in the bolt is not to exceed 100 N/mm2.

9. A cover plate is bolted on the flanged end of a pressure vessel through 6 bolts. The inner
diameter of the pressure vessel is 200mm and is subjected to an internal pressure of 10

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MPa. Selecting carbon steel C40 (σ y = 328.6 MPa) as the material for the bolts determine
the size of the bolt, considering initial tension for the following cases: a) Metal to metal
joints, b) A copper gasket.

10. A steel bolt of M20 is used to connect two plates of each 16mm thick. A soft copper of
gasket of 3 mm thick is used in between the plates of joint to be leak proof. The outside and
inside diameters of gasket are 50mm and 22 mm respectively. Take modulus of elasticity of
bolt material as 200 Mpa and for gasket material as 120 MPa. The bolt is subjected to an
axial load of 15 kN. Determine the stress induced in the bolt.

Module 4

1. What are the different types of welded joints?

2. A circular shaft, 50mm in diameter is welded to a support by means of a fillet weld as

shown in the figure. Determine the size of the weld if the permissible shear stress in the
weld is limited to 100 N/m2.

2. What are riveted joins? What are its advantages and disadvantages of riveted joints over
welded joins? Explain. Also explain the type of rivet heads.

3. Determine the load carrying capacity of a welded joint as shown in figure below. The
size of weld is 10mm and allowable shear stress in the weld is 66Mpa.

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4. Design a triple riveted zigzag lap joint to connect two plates each 12mm thick. Draw a
neat sketch of the joint.

5. Design a triple riveted double covered butt joint with unequal cover plates to connect
two plates of 20mm thickness. Use permissible values of tensile, compressive and shear
stress are 90 N/mm2, 150 N/mm2 and 60 N/mm2 respectively.

6. Determine the size of the weld for a bracket welded as shown in figure below. Allowable
shear stress in the weld is 90 MPa.

7. A double riveted double cover butt joint in plates 20mm thick is made with 25mm
diameter rivets at 100 mm pitch. The permissible stresses are: Tensile =120 MPa, Shear
stress 100 MPa, crushing stress =150 Mpa. Find the efficiency of joint, taking the strength of
the rivet in double shear as twice than that of single shear.

8. Design a double riveted butt joint with two cover plates for the longitudinal seam of a
boiler shell 1.5m in diameter is subjected to a steam pressure of 0.95 N/mm2. Assume joint
efficiency as 75%, allowable tensile stress in the plate 90MPa, compressive stress 140Mpa
and shear stress in the river 56 MPa.

9. Find the maximum shear stress induced in the weld of 6 mm size when a channel, as
shown in figure below, is welded to a plate and loaded with 20kN force at a distance of
200mm.

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10. A rectangular steel plate is welded as a cantilever to a vertical column and supported a
single concentrated load P, as shown in figure below. Determine the weld size if shear
stress is not exceed 140 MPa.

11. Design a cotter joint to support a load varying from 30 kN in compression to 30 kN in

tension. The material used is carbon steel for which the following allowable stress may be
used. The load is applied statically. Tensile stress= compressive stress= 50 MPa; shear
stress = 35 MPa, and crushing stress = 90 Mpa.

Module 5

1. A helical compression spring of a cam-mechanism is subjected to an initial pre load of 50

N. The maximum operating force during the load cycle is 150N. The wire diameter is 3 mm
while the mean coil diameter is 18mm. The spring is made of oil hardened and tempered
valve spring wire of grade–SW (Sut =1430N/mm2). Determine the factor of safety used in
the design on the basis of fluctuating stress.

2. Design a helical spring for a safety valve. The valve must blow off at a pressure of 1.2
MPa and should lift by 3mm for 5% increase in pressure. The valve diameter is 60mm. The
maximum allowable shear stress is 400 MN/m2 and the modulus of rigidity is 82.7 Gpa.
Assume the spring index as 8.

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3. The load on a steel helical compression spring varies from 500 N to 1200 N. The spring
index is 6 and the desired factor of safety is 1.3. Determine the required wire size by taking
yield shear stress as 600 MN/m2 and the endurance shear stress as 300 MN/m2.

4. A semi elliptical laminated spring is to carry a load of 600N and consists of 8 leaves
46mm wide, two of the leaves being of full length. The spring is to be made 1000mm
between the eyes and is held at the centre by a 60 mm wide band. Assume that the spring is
initially stressed so as to induce an equal stress of 500 N/mm2 when fully loaded. Design
the spring giving a) thickness of leaves b) eye diameter c) length of leaves d) maximum
deflection and radius to which the leaves should be initially bent.

5. A helical compressed 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. The yield stress in shear is 770 MPa and endurance stress in shear is 350 Mpa, find:
(a) size of the spring wire, (b) Diameter, (c) Number of turns of the spring and (d) Free
length of the spring. The compression of the spring at the maximum load is 30mm. The
modulus of rigidity of the material may be taken as 80 kN/mm2.

6. Design a helical compression spring for a maximum load of 1000 N for a deflection of 25
mm using the value of spring index as 5. The maximum permissible shear stress for spring
wire is 420 MPa and modulus of rigidity is 84 kN/mm2.

7. The load on a steel helical compression spring varies from 500 N to 1200 N. The spring
index is 6 and the desired factor of safety is 1.3. Determine the required wire size by taking
yield shear stress as 600 MN/m2 and the endurance shear stress as 300 MN/m2.

8. An automotive single plate clutch, with two pairs of friction surfaces, transmits 300 Nm
torque at 1500rpm. The inner and outer diameters of the friction disk are 170 and 270mm
respectively. The coefficient of friction is 0.35. The normal force on the friction surfaces is
exerted by nine helical compression springs, so that the clutch is disengaged when the
external force further compressed the springs. The spring index is 5 and the number of
active coils is 6. The springs are made of patented and cold-drawn steel wires of grade 2.
(G=81370 N/mm2 ). The permissible shear stress for the spring is 30% off the ultimate
tensile strength. Design the spring and specify their dimensions.

9. A concentric spring consists of two helical compression springs having the same free
length. The composite spring subjected to a maximum force of 2000 N. The wire diameter
and mean coil diameter of inner spring are 8mm and 64mm respectively. Also, the wire
diameter and mean coil diameter of the outer spring are 10 and 90 mm respectively. The
number of active coils in inner and outer springs is 12 and 8 respectively. Assume same
material for two springs and the modulus of rigidity of spring material is 81370 N/mm2.

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Calculate a) The force transmitted by each spring, b) The maximum deflection of the spring
and c) The maximum torsional shear stress induced in each spring.

10. A helical compression spring of the exhaust valve mechanism is initially compressed
with a preload of 375 N. When the spring is further compressed and the valve is fully
opened, the torsional shear stress in the spring wire should not exceed 750 N/mm2. Due to
space limitations, the outer diameter of the spring should not exceed 42 mm. The spring is
to be designed for minimum weight. Calculate the wire diameter and the mean coil
diameter of the spring.

Module 6

1. A steel shaft is subjected to a bending moment of 9kNm and a twisting moment of

12kNm. The yield strength of steel is 360 Mpa in tension and compression and the
Possion’s ratio is 0.3. If a factor of safety of 2 with respect to failure is specified, determine
the permissible diameter of the shaft according to (a) Maximum shear stress theory of
failure, (b) maximum normal stress theory of failure (b) Maximum distortion theory of
failure.

2. Design a bushed pin type of flexible coupling to connect a pump shaft to a motor shaft
transmitting 30kW at 900 rpm. The overall torque is 15% more than mean torque. The
material allowable properties area as follows: stress (in crushing for shaft and key
material)= 80 MPa, Shear stress (in shear for shaft and key material)= 40 MPa, Shear stress
(in shear for cast iron)= 15 MPa. Material of the pin is as same as the shaft and the key.
Draw the sketch of the coupling.

3. A hollow transmission shaft having inside diameter 0.6 times the outside diameter is
made of plain carbon steel 40 C8 (Syt = 380N/mm2) and the factor of safety is 3. A belt
pulley 1000 mm in diameter is mounted on the shaft which overhangs the left hand bearing
by 250mm. The belts are vertical and transmit power to the machine shaft below the
pulley. The tensions on the tight and slack side of the belt are 3kN and 1kN respectively,
while the weight of the pulley is 500N. The angle of wrap of belt on the pulley is 180
degree. Calculate the outside and inside diameter of the shaft.

4. Briefly explain keys, advantage and their application.

5. Design a protected type flange coupling to transmit power between two shafts 40 mm
and 50mm. The allowable shear stress for the shaft and the bolts is 60MPa. The allowable
shear stress and bearing stress for key are 54 MPa and 120 MPa respectively. For IC flange,
the allowable shear stress is 6MPa.

6. A SAE 1045steel rod of σy 309.9 MPa with 80mm diameter is subjected to bending
moment of 3 kN-m and torque T. Taking factor of safety as 2.5, find the maximum value of

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ME403 DESIGN OF MACHINE ELEMENTS 1 S7 ME

torque ‘T’ that can be safely carried by rod according to : (a) Maximum normal stress
theory; (b) Maximum shear stress theory.

7. A simply supported shaft carries a pulley at the centre. The torque on pulley varies
between 120Nm and 200Nm and the bending moment varies between 300Nm and -
150Nm. The material of shaft has an ultimate stress of 600 MPa and yield stress of 450
MPa. Endurance stress may be taken as half the ultimate stress. The stress concentration
factor for the shaft is 1.3 in bending and 1.2 in torsion. Take factor of safety as 1.8. The size
and surface factor are 0.83 and 0.9 respectively.

8. Design a rigid CI flange coupling to transmit 18kW of power at 1440 rpm. The allowable
shear stress for flange is 4MPa. The shaft, key and bolts are made of annealed steel having
allowable shear stress for flange in 4 MPa. The shaft, keys and bolts are made of annealed
steel having allowable shear stress of 93 MPa. Allowable crushing stress for key =186 MPa.

9. A mild steel shaft transmits 15kW of power at 300rpm. It is supported on two bearings
1.2m apart. The shaft receives power through a 450mm diameter pulley mounted at
300mm to the right of the right bearing. The power is given out through a 300m diameter
gear mounted at 250mm to the right of the left bearing. The belt drive is horizontal and the
gear drive with a downward tangential force. Find the suitable diameter of the shaft if yield
stress for the shaft material is 234 MPa and the factor of safety is 2.0. Take shock and
fatigue factor as 1.5. Ratio of tension in belt is 3.0.

10. Design a shaft to transmit power from an electric motor to a lathe head stock through a
pulley by means of a belt drive. The pulley weights 200N and is located at 300mm from the
centre of the bearing.. The diameter of the pulley is 200mm and the maximum power
transmitted is 1kW at 120rpm. The angle of lap of the belt is 180 degrees and coefficient of
friction between the belt and the pulley is 0.3. The stock and failure 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.

Prepared by Approved by

Mr. Joseph Babu K. Dr.Thankachan T Pullan

(Faculty, ME) (HOD, ME)

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