HALDIA INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

QUESTION BANK

FOR 3RD YEAR, 5TH SEMESTER

DESIGN OF MACHINE ELEMENTS (PC-ME 503)

 Haldia Institute of Technology
Department of Mechanical Engineering
Design of Machine Elements (PC-ME 503)

Module 2
1) A cylindrical shaft made of steel of yield strength 700MPa is subjected to static loads
consisting of bending moment 10 kN-m and a torsional moment 30 kN-m. Determine the
diameter of the shaft using maximum shear stress theory of failure assuming a factor of safety
of 2.
2) A mild steel shaft of 50mm diameter is subjected to bending moment of 2 kN-m and a torque
T. If the yield point of the steel in tension is 200 MPa, find the maximum value of this torque
without causing yielding of the shaft according to maximum shear stress theory and
maximum distortion energy theory of failure. Assume suitable factor of safety.
3) A C-clamp as shown in Fig. 1, carries a load P = 25 kN. The cross-section of the clamp is
rectangular having width equal to twice thickness. Assuming that the clamp is made of steel
casting with as allowable stress of 100 MPa, find its dimension.

Fig 1 Fig 2

4) An overhang crank, as shown in Fig. 2 carries a tangential force of 10 kN at the centre of the
crankpin. Find the maximum principal stress and the maximum shear stress at the centre of
the crank shaft bearing.

5) A steel bracket is subjected to a load of 4.5 kN, as shown in Fig. 3. Determine the required
thickness of the bracket in order to limit the tensile stress to 70 MPa.

6) A bracket, as shown in Fig. 4 is bolted to the framework of a machine which carries a load P.
The cross-section at 40 mm from the fixed end is rectangular with dimensions, 60 mm× 30
mm. If the maximum stress is limited to 70 MPa. Find the value of P.

7) The shaft of an overhang crank subjected to a force P of 1 kN is shown in Fig. 5. The shaft is
made of plain carbon steel 45C8 and the tensile yield strength is 380 N/mm 2. The factor of
safety is 2. Determine the diameter of the shaft using the maximum shear stress theory.

2 Question Bank
 Haldia Institute of Technology
Department of Mechanical Engineering
Design of Machine Elements (PC-ME 503)

Fig 3 Fig 4

Fig 5

3 Question Bank
 Haldia Institute of Technology
Department of Mechanical Engineering
Design of Machine Elements (PC-ME 503)

Module 3
1) A circular bar of 500 mm length is supported freely at its two ends. It is acted upon by a
central concentrated cyclic load having a minimum value of 20 kN and a maximum value of
50 kN. Determine the diameter of the bar by taking a factor of safety of 1.5, size factor is
0.85, surface finish factor is 0.9. The ultimate strength is 650 MPa, yield strength is 500 MPa
and endurance strength is 350 MPa. Ans: 62.1 mm.

2) A cantilever beam made of cold drawn carbon

steel of circular cross-section as shown in
figure. It is subjected to a load which varies
from –F to 3F. Determine the maximum load
that this member can withstand for an indefinite
life using a factor of safety as 2. The theoretical
stress concentration factor is 1.42 and the notch
sensitivity factor is 0.9. The ultimate stress is
550 MPa, yield stress 470 MPa, endurance limit
275 MPa, size factor 0.85 and surface finish
factor 0.89. Ans: 57.3N
3) A steel cantilever is 200 mm long shown in figure. It is subjected to an axial load which
varies from 150 N compression to 450 N tension and also a transverse load at its free end
which varies from 80 N up to 120 N down. The cantilever is of circular cross-section. It is of
diameter 2d for the frst 50 mm and diameter d for the remaining length. Determine the
diameter taking a factor of safety of 2. Assume the following values: Yield stress: 330 MPa,
Endurance limit: 300 MPa, load correction factor: 0.7 for axial loading & 1.0 for bending,
stress correction factor: 1.44 for bending & 1.64 for axial loading, size factor: 0.85, surface
factor: 0.9 and notch sensitivity factor: 0.9. Ans: 12.9 mm

4) 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 from -150 N-m to +400 N-m as the torque on the shaft
varies from -50 N-m 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 torsion are 1.6 and 1.3
respectively. Take factor of safety 1.5, load correction factor 1.0 for bending and 0.6 for
torsion, size factor 0.85 and surface factor 0.88. Ans: 35 mm.
5) A cantilever beam made of cold drawn steel 20C8 (S ut = 540 MPa) is subjected to a
completely reversed load of 1000 N as shown in figure. The notch sensitivity factor is 0.85
and the expected reliability is 90%. Determine the diameter d of the beam for a life of 10000
cycles. Ans: 17.05 mm.

4 Question Bank
 Haldia Institute of Technology
Department of Mechanical Engineering
Design of Machine Elements (PC-ME 503)

Module 4
1) It is required to design a cotter joint to connect two steel rods of equal diameter. Each rod is
subjected to an axial force of 50 kN. Design and draw the joint and specify its main
dimensions. The material is taken as plain carbon steel of Grade 30C8 (S yt = 400N.mm2).
Take factor of safety for rods, spigot and socket is 6 and for cotter it is 4.
2) Design and draw a cotter joint to support a load of varying from 30 kN in tension to 30 kN in
compression. The material used is carbon steel for which the following allowable stresses
may be used. The load is applied statically. Tensile stress = compressive stress = 50 MPa;
Shear stress = 90 MPa.
3) It is required to design a knuckle joint to connect two circular rods subjected to an axial
tensile force of 150 kN. Design and draw the joint and specify the dimensions of its
components. The allowable stresses for the material are taken as 75 MPa in tension, 60 MPa
in shear and 150 MPa in compression.
4) It is required to design a knuckle joint to connect two circular rods subjected to an axial
tensile force of 50 kN. Design and draw the joint and specify the dimensions of its
components. The material is taken as plain carbon steel of Grade 30C8 (S yt = 400N.mm2).
Take factor of safety 5 for all the components.
5) A knuckle joint is subjected to an axial load of 90 kN. Assume that the thickness of the eye is
to be 1.5 times the diameter of the pin. The allowable stress of the material in tension and
compression due to bending is 60 MPa and the allowable stress in shear is 30 MPa. The
allowable bearing stress is 20 MPa. Determine the required pin diameter. (WBUT 2011).
6) A shaft of rectangular cross-section is welded to a support by means of fillet welds as shown
in figure. Determine the size of the welds, if the permissible shear stress in the weld is limited
to 75 MPa.

7) A plate 75 mm wide and 12.5 mm thick is joined with another plate by a single transverse
weld and a double parallel fillet weld as shown in figure. The maximum tensile and shear

5 Question Bank
 Haldia Institute of Technology
Department of Mechanical Engineering
Design of Machine Elements (PC-ME 503)

stress are 70 MPa and 56 MPa respectively. Find the length of each parallel fillet weld, if the
joint is subjected to both static and fatigue loading.(WBUT 06)

8) A welded connection of steel plates is shown in figure. It is subjected to an eccentric force of

50 kN. Determine the size of the weld, if the permissible shear stress in the weld is not to
exceed 70 MPa.

9) A plate bracket welded to a steel column and loaded eccentrically shown in figure. Assuming
that the size of the weld is 6 mm × 6mm, determine the maximum stress induced in the weld.
(WBUT 08)

10) An eccentrically loaded bracket is welded to support as shown in figure. The permissible
shear stress for the weld material is 55 MPa and the load is static. Determine the throat and
leg dimensions for the welds. All the dimensions in the figure are in mm. (WBUT 09)

6 Question Bank
 Haldia Institute of Technology
Department of Mechanical Engineering
Design of Machine Elements (PC-ME 503)

11) A 75 mm diameter solid shaft is welded to a flat plate as shown in figure. If the size of the
weld is 20 mm, find the maximum normal and shear stress in the weld. (WBUT 09)

Module 5
1) Two mild steel tie bars, for a bridge structure are to be joined by means of a butt joint with
double straps. The thickness of the tie bar is 12 mm and carries a tensile load of 400 kN.
Design the joint completely taking the allowable stresses as 100 MPa for tensile, 75 MPa for
shear and 150 for crushing. (WBUT 11)
2) The following data apply to the C clamp shown in figure trapezoidal thread:
a. 5 threads per cm (single threaded)
b. Outside diameter = 12 mm
c. Coefficient of thread friction = 0.25
d. Mean collar radius = 6.4 mm
e. Load = 4500 N
Force exerted by the operator at the end of the lever = 90 N
Determine
i. Length of the handle L
ii. Maximum shear stress in the body of the screw and where this exists.
iii. Bearing pressure on the threads
3) A bearing housing shown in the figure is fastened to a frame by 6 bolts spaced equally on a
250 mm PCD of which 2 are positioned on the horizontal line. The bearing flange diameter is
300 mm and a load of 50 kN is applied at 275 mm from the frame. Determine the size of the
bolts. The material of the bolt is C20 having yield strength of 245 MPa and factor of safety is
3. (WBUT 11)

4) A bracket is riveted to a column by six rivets of equal size as shown in figure. Shear stress in
the rivet is limited to 15 MPa. Determine the diameter of the rivet. (WBUT 11)

7 Question Bank
 Haldia Institute of Technology
Department of Mechanical Engineering
Design of Machine Elements (PC-ME 503)

5) A vertical two start square threaded screw of a 100 mm mean diameter and 20 mm pitch
supports a vertical load of 20 kN. An axial thrust on the screw taken by a collar bearing of
250 mm outside diameter and 100 mm inside diameter. Find the force required at the end of a
lever which is 400 mm long in order to lift and lower the load. The coefficient of friction for
the vertical screw and nut is 0.15 and that for collar bearing is 0.20. (WBUT 08)
6) A tie bar in a bridge is 350 mm wide and 20 mm thick. It is connected to a gusset of the same
thickness by a double cover butt joint. Determine the diameter of the rivet and number of
rivets required. (WBUT 08)
7) A bracket as shown in the figure is fixed to a vertical column by means of five stand bolts.
Determine: i) the diameter of fixing bolts and ii) the thickness of the arm of the bracket.
Assume safe working stresses of 70 MPa in tension and 50 MPa in shear. (WBUT 08)
8) A bracket is riveted to a column by 6 rivets of equal size as shown in figure. It carries a load
of 100 kN at a distance of 250 mm from the column. If the maximum shear stress in the rivet
is limited to 63 MPa, find the diameter of the rivet. (WBUT 06)

9) Determine the size of the bolts and the thickness of the arm for the bracket as shown in figure.
If it carries a load of 40 kN at an angle of 60˚ to the vertical. Given that, σ t = 70 MPa, σc =
105 MPa and τ = 50MPa.

8 Question Bank
 Haldia Institute of Technology
Department of Mechanical Engineering
Design of Machine Elements (PC-ME 503)

Module 6
1) The shaft shown in figure is driven by pulley B from an electric motor. Another belt drive
from pulley A is running a compressor. The belt tensions for the pulley A are 1500 N and 600
N. the ratio of belt tensions for pulley B is 3.5. The dia of pulley A is 150 mm and the dia of
pulley B is 480 mm. the allowable tensile stress for the shaft material is 170 MPa and the
allowable shear stress is 85 MPa. Taking torsion and bending factors as 1.25 and 1.75
respectively, find the dia of the shaft.

2) Design a cast iron protective type flange coupling to transmit 15 kW at 900 r.p.m. from an
electric motor to a compressor. The service factor may be assumed as 1.35. The permissible
stresses are: Shear stress for shaft, bolt and key material = 40 MPa, Crushing stress for bolt
and key = 80 MPa and shear stress for cast iron = 8 MPa.
3) A hollow circular shaft is being designed to transmit 120 kW at 105 rpm. The inside diameter
of the shaft is to be one-half of the outside diameter. Assuming that the allowable shear stress
is 45 MPa, calculate the minimum required outside diameter. (WBUT 11)
4) An overhung shaft carries a pulley of 1000 mm diameter, whose centre is 250 mm from the
centre of the nearest bearing. The weight of the pulley is 600 N and the angle of lap of the belt
may be assumed as 180˚. The pulley is driven by a motor, placed below it at an angle of 45˚.
If the permissible tension in a belt is 2500 N and coefficient of friction is 0.3, determine the
size of the shaft. Assume the permissible shear stress in the shaft material as 50 MPa. Take
shock and fatigue factor in tension and bending as 2 and 1.5 respectively.
5) Design a bushed-pin type of flexible coupling to connect a pump shaft to a motor shaft
transmitting 40 kW at 1000 rpm. The overall torque is 25 percent more than the mean torque.
The allowable shear and crushing stress for shaft and key material is 40 MPa and 80 MPa

9 Question Bank
 Haldia Institute of Technology
Department of Mechanical Engineering
Design of Machine Elements (PC-ME 503)

respectively. The allowable shear stress for cast iron is 15 MPa. The allowable bearing
pressure for rubber bush is 0.8 MPa. The material of the shaft, key and pin is same.
6) It is required to select a flat belt drive for a compressor running at 720 rpm which is driven by
a 25 kW, 1440 rpm motor. Centre distance between the pulleys is 3 m. The belt is open type.
The load correction factor is 1.3 and arc correction factor is 1.09. Belt rate is 0.0118 kW/mm
width at 5.08 m/s belt velocity. Give the belt specification.
7) A shaft is supported by two bearings placed 1 m apart. A 600 mm diameter pulley is mounted
at a distance of 300 mm to the right of the left hand bearing and this drives a pulley directly
below it with the help of belt having maximum tension of 2.25 kN. Another pulley of 400 mm
diameter is placed at 200 mm to the left of the right hand bearing and driven with the help of
electric motor and belt, which is placed horizontally to the right. The angle of contact for both
pulleys is 180˚ and μ = 0.24. Determine the suitable diameter for a solid shaft, allowing
working stress of 63 MPa in tension and 42 MPa in shear for the material of shaft. Assume
that the torque on one pulley is equal to that on the other pulley.
8) A shaft made of mild steel is required to transmit 100 kW at 300 rpm. The supported length of
the shaft is 3 meters. It carries two pulleys each weighing 150 N supported at a distance of 1
meter from the end respectively. Assuming the safe value of stress determine the diameter of
the shaft.

Module 7
1) A helical compression spring, made of circular wire, is subjected to an axial load, which
varies from 2.5 kN to 3.5 kN. Over this range of force, the deflection of the spring is
approximately 5mm. The spring index can be taken as 5. The spring has square and ground
ends. The material of the spring is patented cold-drawn steel wire with ultimate tensile
strength of 1050 MPa and modulus of rigidity of 81370 MPa. The permissible shear stress of
the spring wire may be taken as 50 % of the ultimate tensile strength. Design the spring and
find out: (i) wire diameter, (ii) mean coil diameter, (iii) number of active coils, (iv) total
number of coils, (v) solid length of the spring, (vi) free length of the spring, (vii) required
spring rate and (viii) actual spring rate.
2) A closely coiled helical spring is made of 10 mm diameter steel wire, the coil consisting of 10
complete turns with a mean diameter of 120 mm. The spring carries an axial pull of 200 N.
Determine the shear stress induced in the spring neglecting the effect of stress concentration.
Determine also the deflection in the spring, its stiffness and strain energy stored by it if the
modulus of rigidity of the material is 80 GPa.
3) A vertical two start square threaded screw of a 100 mm mean diameter and 20 mm pitch
supports a vertical load of 20 kN. An axial thrust on the screw is taken by a collar bearing of
250 mm outside diameter and 100 mm inside diameter. Find the force required at the end of a
lever which is 400 mm long in order to lift and lower the load. The coefficient of friction for
the vertical screw and nut is 0.15 and that for collar bearing is 0.20.
4) A safety valve of 60 mm diameter is to blow off at a pressure of 1.2 MPa. It is held on its seat
by a close-coiled helical spring. The r maximum lift of the valve is 10 mm. Design a suitable
compression spring of spring index 5 and providing an initial compression of 35 mm. The
maximum shear stress in the material of the wire is limited to 500 MPa. The modulus of
rigidity for the spring material is 80 MPa. Calculate: (i) diameter of the spring wire, (ii) mean
coil diameter, (iii) number of active turns and (iv) pitch of the coil.

10 Question Bank
 Haldia Institute of Technology
Department of Mechanical Engineering
Design of Machine Elements (PC-ME 503)

5) Design a helical compression spring for a maximum load of 1 kN for a deflection of 25 mm

using the value of spring index 5. The maximum permissible shear stress for spring wire is
420 MPa and modulus of rigidity is 84 GPa.
6) A helical spring is made from a wire of 6mm diameter and has outside diameter of 75mm. If
the permissible shear stress is 350 MPa and modulus of rigidity 84 GPa, find the axial load
which the spring can carry and the deflection per active turn.

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