K. J.

Somaiya College of Engineering, Mumbai-77

DEPARTMENT OF MECHANICAL ENGINEERING
EMD PRACTICAL (2022-23)

Practical No: 1

1. A steel rod 20 mm diameter is encased with in a copper tube of internal diameter 25 mm

and thickness of metal as 5 mm. The ends of rod and the tube are rigidly connected to each
other. The length of this composite bar is 1 m. The composite rod is subjected to axial load
of _____ KN. At this instant, when this composite bar is heated through 250°C, find the
resultant stresses induced in both the metals. Also find the final length of the bar. Assume
Es = 210 GPA. αs = 11.5 x I0-6 per °C. Ec = 105 GPA. αc = 17 x I0-6 per °C.

2. A beam of I-section having top flange (100 mm X 20 mm) web (20 mm x 100 mm) and
bottom flange (180 mm x 20 mm) is supported on an overhang beam with loading as
shown in Figure. Calculate the maximum value of W if allowable bending stresses are __
MPA in tension and ___ MPA in compression. Find also radius of curvature at mid span
for maximum load W. Take E = 200 GPA.

3. A cantilever bracket is under the action of load P = _____ KN as shown. Determine the resultant
normal stresses at layers A and B of the fixed end.

4. A hollow shaft is 1 m long and has external diameter _____ mm. It has 20 mm internal
diameter for a part of length and 30 mm internal diameter for the rest of the length. If the
maximum shear stress is not to exceed _____ MPA, determine the maximum power
transmitted by it at a speed of 300 RPM. If the twists produced in the two portions of the
shaft are equal, find the lengths of the two portions.

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 K. J. Somaiya College of Engineering, Mumbai-77
DEPARTMENT OF MECHANICAL ENGINEERING
EMD PRACTICAL (2022-23)

Practical No: 2
1. It is required to standardise load-carrying capacities of dumpers in a manufacturing unit.
The maximum and minimum capacities of such dumpers are 40 and 630 kN, respectively.
The company is interested in developing seven models in this range. Specify their load
carrying capacities.

2. Explain various theories of failure, showing the figures of region of safety.

3. A rotating shaft of 16 mm diameter is made of plain carbon steel ____. It is subjected to a

tensile load of ____N, with a steady torque of____ Nm, and the maximum bending
moment of ___Nm.
Calculate factor of safety based on
i) Maximum Normal stress theory
ii) Maximum Shear stress theory
iii) Maximum Strain Energy theory
iv) Distortion Energy theory

Practical No: 3
1. Design a cotter joint to transmit a load of ….. KN. Select suitable materials, factor of
safety and draw the useful sketches.
(Draw assembly and detail drawing of cotter joint using Solid Works with the dimensions
of your own design.)

2. A pillar crane has a circular base of 750 mm diameter, which is fi xed to the concrete base
by four identical bolts, equally spaced on the pitch circle of 600 mm diameter as shown in
Figure. The bolts are made of steel _____ and the factor of safety is 5. The maximum load
is ___ kN which acts at a radius of 750 mm from the axis of the crane. Determine the size
of the bolts if,
i) the load acts in plane-XX at the point P1;
ii) the load acts in plane-YY at Point P2.

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 K. J. Somaiya College of Engineering, Mumbai-77
DEPARTMENT OF MECHANICAL ENGINEERING
EMD PRACTICAL (2022-23)

Practical No: 4

1. A welded joint, as shown in Figure, is subjected to an eccentric load of _______N. Find

the size of the weld, if the maximum shear stress in the weld is not to exceed____N/mm2.

2. A C- clamp is designed to exert a force of ___ kN. Select suitable material for screw, nut
and the frame. Design screw and nut for press. Assume throat height of press is 200 mm.
Consider I section for the frame and design horizontal section of the frame if inner edge of
the frame is at a distance of 125 mm from the screw axis.

Practical No: 5

1. A cold drawn steel rod of circular cross-section is subjected to a variable bending moment
of ____ Nm to ___ N-m as the axial load varies from _____ N to ______ N. The
maximum bending moment occurs at the same instant that the axial load is maximum.
Determine the required diameter of the rod for a factor of safety 2. Neglect any stress
concentration and column effect. Assume the following values:
i. Ultimate strength = 550 MPa
ii. Yield strength = 470 MPa
iii. Size factor = 0.85
iv. Surface finish factor = 0.89
v. Correction factors = 1.0 for bending
= 0.7 for axial load
The endurance limit in reversed bending may be taken as one-half the ultimate strength.

2. Design a closed coil helical compression spring for maximum load of ___ N for a
deflection of ___ mm. Assume spring index of 6. The maximum permissible shear stress
for spring wire is 450 N/mm2 and modulus of rigidity is 84 kN/mm2.

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 K. J. Somaiya College of Engineering, Mumbai-77
DEPARTMENT OF MECHANICAL ENGINEERING
EMD PRACTICAL (2022-23)
3. A semi-elliptical laminated spring is to carry a load of ___KN and consists of 8 leaves
of __mm wide, two of the leaves being of full length. The spring is to be made __ mm
between the eyes and is held at the center by a ___mm wide band. Assume that the spring
is initially stressed so as to induce an equal stress of ___N/mm2, when fully loaded.
Design the spring giving

a) Thickness and width of the leaves

b) Eye diameter
c) Length of all leaves
d) Radius of curvature
e) Deflection of spring. Assume E = 2×105 N/mm2

Practical No: 6

1. A shaft is housed in the bearing ___ m apart. A 600 mm diameter pulley is mounted at a
distance of 250 mm to the right of left hand bearing and this drives a pulley directly
below it with the help of belt having maximum tension of ___ kN. Another pulley400 mm
diameter is placed 350 mm to the left of right hand bearing and is driven with the help of
electric motor and belt, which is placed horizontally to the right. The angle of contact for
both the pulleys is 180° and μ = ___. Determine the suitable diameter for a solid shaft,
allowing working stress of 80 MPa in tension and 50 MPa in shear for the material of
shaft.

2. Design a bush pin type flexible coupling along with keys and shaft to connect and
transmit ___ kW power at ___rpm. The starting torque of motor is 130 % of the rated
torque. Select suitable material and factor of safety for the various components.

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 K. J. Somaiya College of Engineering, Mumbai-77
DEPARTMENT OF MECHANICAL ENGINEERING
EMD PRACTICAL (2022-23)

Practical No: 7

1. A deep grove ball bearing no ____ works on following load cycle.

Sr. No Radial Axial Load Speed Duration

Load (kN) (kN) (RPM) (Min.)
1
2
3

Under each phase of load with heavy shocks. Determine expected life of bearing in hours
with _____ % probability of survival.

2. Design flat belt drive to transmit _____ kW at _____ rpm with velocity ratio _____
having center distance of _____ m. Design shafts and decide suitable pulley construction.

3. Design the pair of helical gears to transmit ……. kW at 20 revolutions per second. The
gear ratio for the drive is…......The helix angle is 17o and considers 20o full depth teeth.
Select suitable material with suitable application.

Practical No: 8

1. Stress analysis of Cotter Joint (Taking own design values and Solid Works drawing for the same).

Practical No: 9

1. Use of Matlab (Simscape) software

Note: At least 8 Practical out of above 9 is mandatory to complete.

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