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Roll No:
(To be filled in by the candidate)
PSG COLLEGE OF TECHNOLOGY, COIMBATORE - 641 004
SEMESTER EXAMINATIONS JULY 2018
BE / BE(SW) – MECHANICAL ENGINEERING Semester : 5
12M503 DESIGN OF MACHINE ELEMENTS
Time : 3 Hours Maximum Marks : 100
INSTRUCTIONS:
1. Answer ALL questions. Each question carries 20 Marks.
2. Subdivision (a) carries 3 marks each, subdivision (b) carries 7 marks each and subdivision
(c) carries 10 marks each.
3. PSG DESIGN DATA BOOK is permitted

1. a) It is required to standardize load carrying capacities of dumpers in a manufacturing

unit. The maximum and minimum capacities of such dumpers are 40 kN and 630 kN
respectively. The company is interested in developing seven models in this range.
Specify their load carrying capacities.
b) A bracket, made of steel FeE 200 (Syt = 200 N/mm2) and subjected to a force of 5 kN
acting at an angle of 300 to the vertical, is shown in Fig.1. The factor of safety is 4.
Determine the dimensions of the cross section of the bracket

250

Fig.1 Fig 2
c) A cantilever beam made of cold drawn steel 40C8 (Sut = 600 N/mm2 and
Syt = 380 N/mm2) is shown in Fig. 2. The force P acting at the free end varies from
—50 N to +150 N. The expected reliability is 90% and the factor of safety is 2. The
notch sensitivity factor at the fillet is 0.9. Determine the diameter 'd' of the beam at
the fillet cross-section
2. a) With neat sketch differentiate the taper key and woodruff key. State two applications
of each type of key.
b) A bushed pin type flexible coupling is used to connect two shafts and transmit 6 kW
power at 740 rpm. Shafts, keys and pins are made of commercial steel (S yt = Syc =
245 N/mm2) and the factor of safety is 3. The flanges are made of grey cast iron FG
200 (Sut = 200 N/mm2) and the factor of safety is 6. Assume, Ssy = 0.5Syt and
Ssu= 0.5Sut There are 4 pins. The pitch circle diameter of the pins is four times the
shaft diameter. The permissible shear stress for the pins is 40 N/mm 2. The
permissible bearing pressure for the rubber bushes is 1 N/mm2. The keys have a
square cross-section. Calculate: (i) diameter of the shafts; (ii) dimensions of the key;
(iii) diameter of the pins; and (iv) outer diameter and effective length of the bushes.

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c) A transmission shaft supporting a helical gear B and an overhung bevel gear D is

shown in Fig.3. 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
forces is 450 mm. Power is transmitted from the helical gear to the bevel gear. The
gears are keyed to the shaft. The material of the shaft is steel 45C8 (Sut = 600 and
Syt = 380 N/mm2). The factors kb and kt of ASME code are 2.0 and 1.5 respectively.
Determine the shaft diameter using the ASME code.

Fig.3
3. a) What are the four different styles of end for helical compression spring?
b) A semi-elliptic leaf spring consists of two extra full-length leaves and eight graduated
length leaves, including the master leaf. The centre-to-centre distance between the
two eyes of the spring is 1 m. The maximum force acting on the spring is 10 kN and
the width of each leaf is 50 mm. The spring is initially pre-loaded in such a way that
when the load is maximum, the stresses induced in all the leaves are equal to 350
N/mm2. The modulus of elasticity of the leaf material is 207000 N/mm2. Determine
the (i) thickness of leaves; and (ii) the deflection of the spring at maximum load.
c) i) A transmission shaft, supporting two pulleys A and B and mounted between two
bearings C1 and C2 is shown in Fig.4. Power is transmitted from the pulley A to B.
The shaft is made of plain carbon steel 45C8 (Sut = 600 and Syt = 382 N/mm2). The
pulleys are keyed to the shaft. Determine the shaft diameter using the ASME code
if, kb=1.5 and kt= l. Also, determine the shaft diameter on the basis of torsional
rigidity, if the permissible angle of twist between the two pulleys is 0.5° and the
modulus of rigidity is 79400 N/mm2

Fig.4

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(OR)
ii) In an automotive plate clutch, six helical compression springs arranged in parallel
provide the axial thrust of 1800 N. The springs are compressed by 12 mm to
provide this thrust force. The springs are identical and the spring index is 6. The
springs are made of cold-drawn steel wires with ultimate tensile strength of 1300
N/mm2. The permissible shear stress for the spring wire can be taken as 50% of
the ultimate tensile strength (G = 81370 N/mm2). The springs have square and
ground ends. There should be a gap of 1 mm between adjacent coils when the
springs are subjected to the maximum force. Design the springs and calculate: (i)
wire diameter; (ii) mean coil diameter; (iii) number of active coils; (iv) total number
of coils; (v) solid length; (vi) free length; (vii) required spring rate; and (viii) actual
spring rate
4. a) Sketch any three different types of cap screws and mention at least one application
for each screw.
b) A crane runway bracket is fastened to the roof truss by means of two identical bolts
as shown in Fig.5. Determine the size of the bolts, if the permissible tensile stress in
the bolts is limited to 75 N/mm2

Fig.5 Fig.6

c) (i) An eccentrically loaded bracket is welded to the support as shown in Fig.6.The

permissible shear stress for the weld is 55 N/mm2 and the load is static.
Determine the throat and leg dimensions for the welds.
(OR)
(ii) A bracket is attached to a steel channel by means of nine identical rivets as
shown in Fig.7. Determine the diameter of the rivets, if the permissible shear
stress is 60 N/mm2

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Fig.7
5. a) Draw a sketch showing the pressure distribution around the periphery of a
hydrodynamic journal bearing.
b) The following data is given for a 360° hydrodynamic bearing: radial load = 10 kN,
journal speed = 1440 rpm, unit bearing pressure = 1000 kPa, clearance ratio
(r/c) = 800 viscosity of lubricant = 30 mPa-s, assuming that the total heat generated
in the bearing is carried by the total oil flow in the bearing, calculate: (i) dimensions of
bearing; (ii) coefficient of friction; (iii) power lost in friction; (iv) total flow of oil;
(v) temperature rise
c) Design a suitable ball bearing for an axial flow compressor to carry a radial load of
2.5 kN and a thrust load of 1.3 kN. The service imposes a light shock factor 1.5 and
bearing will be in use for 35 hours per week for 4 years. The speed of shaft is
900 rpm and diameter of shaft is 45 mm. Assume X = 0.56 and Y = 1.4.

/END/
FD/RL

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