EME Paper Solution MK4I

Summer 2022

Q1. Attempt any FIVE of the following: iii. Application of lever (Foot lever and
a) State any four applications of a cotter joint. hand lever)
Ans: This joint is used between the pistons rod and iv. In governors bell crank levers are
used.
the tail of the pump rod.
v. Levers in Robotics
i. Cotter’s joints are used between the slide spindle
and the fork of the valve mechanism. f) State torsion equation for solid shaft.
ii. Cotter and Dowell arrange to join two parts of a Ans:
flywheel.
iii. Foundation bolt: mainly used for fastening
foundation and construction heavy machines T = torque or twisting moment, N-m

P)
iv. In an automobile engine, the cotter joint is used to τ = shear stress at outer fibre,N/mm2
connect the extension of the piston rod with the d = Diameter of the shaft, mm

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connecting rod in the crosshead. g) State hooks law.

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v. The Cotter joint has historically been used to Ans: Hooke’s law states that stress is directly
connect connecting rods to steam engines and proportional to strain.

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pumps of dumping mines.
vi. It is used in bicycles to connect the paddle to the 2. Attempt any THREE of the following: 12

A
sprocket wheel.
vii. Use in a wet air pump to join a tail rod with the a) Define factor of safety and state it's significance.
piston rod.
viii. It is used to connect two rods of equal diameter
t( Ans: It is defined as the ratio of maximum stress to
the working stress (Design stress).
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𝐌𝐚𝐱𝐢𝐦𝐮𝐦 𝐒𝐭𝐫𝐞𝐬𝐬
subjected to axial forces. Factor of Safety = 𝐖𝐨𝐫𝐤𝐢𝐧𝐠 𝐬𝐭𝐫𝐞𝐬𝐬
b) Define torque or twisting moment state its SI unit.
Significance of Factor of Safety:
D

Ans: Torque is a twisting or turning force that tends

to cause rotation around an axis. i. The nature and reliability of applied load.
ii. The reliability of properties of material
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Its SI unit is N-m.

and change of these properties during
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c) Define stress and state its formula and unit. service.

Ans: Stress is defined as the total force applied per iii. The extent of localized stresses.
on

unit area. iv. The stresses set up during manufacturing.

𝐹𝑜𝑟𝑐𝑒
Stress = v. The extent of loss of life if failure occurs.
𝐴𝑟𝑒𝑎
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Unit is N/m2 b) Write design procedure for turn buckle.

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d) State types of rolling contact bearing. Ans:

Ans:
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i. Deep Groove Ball Bearing

ii. Thrust Ball Bearing
iii. Roller Thrust Ball Bearing
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iv. Taper Roller Bearing

v. Cylindrical Roller Bearing Fig. shows Turn Buckle, Let
vi. Needle Roller Bearing dc = Core diameter of rod.
d = Outer diameter of rod.
e) State any four applications of lever. D = Outer diameter of coupler at end.
Ans: D1 = Inner diameter of coupler at centre.
i. Application of lever in Boilers. D2 = Outer diameter of coupler at centre.
ii. Application of lever in I C Engines. l = Length of threaded portion.

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 EME Paper Solution MK4I
Summer 2022

L = Total length of coupler.

Parts of Turnbuckle
i. Tie rod (dc, d)
ii. Coupler Nut (D, l) Tensile Strength of the Rod
iii. Coupler (D1, D2, L)
Step 1. Decide the design Load (Pd)
For threaded portion the design load is taken 30% Calculate ‘D2’
more than the given load to account for friction in a) By using empirical relation decide L
threads L=6xd
Pd=1.3 P

P)
Step 2. Design of tie rod (dc, d) – c) State any four desirable properties for a good
a) Tensile Failure of rod Considering tensile spring material.
failure of rod, We know that Area resisting Ans:

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tearing The spring material should possess the following

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A=
π
d2 properties.
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i. It should have resilience

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Tensile Strength of the Rod
ii. It should be ductile
iii. It should have high static strength.

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iv. It should have high fatigue strength
Calculate ‘dc’
By using empirical relation
t( v. It should be creep resistant
vi. It should be non-corrosive
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Calculate d=1.15 dc
Step 3. Design of coupler nut (l, D) d) Compare between Ball and Roller Bearings.
a) Tensile Failure of coupler nut Considering Ans:
D

tensile failure of coupler nut, Sr.

Ball bearings Roller bearing
We know that Area resisting tearing No
s

Low load carrying High load carrying

ic

01
Tensile Strength of the Rod capacity. capacity.
on

Rolling elements are Rolling elements are

02
spherical balls. taper rollers.
Calculate ‘D’
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Low initial cost and High initial cost and

b) Shear Failure of coupler nut considering share 03
maintenance cost maintenance cost.
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failure of coupler nut,

We know that Area resisting tearing Radial dimensions are Axial dimensions are
04
A= (π x dc x l) more. more.
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Shear Strength of the Rod

05 Point contact. Line contact.
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3. Attempt any THREE of the following: 12

Calculate ‘l’
Step 4. Design of coupler (D1, D2, L) a) Explain design procedure of bell crank lever with
a) By using empirical relation decide D1 neat sketch.
D1=d + 6 mm Ans: ----------This Numerical is skipped----------
b) Tensile Failure of coupler considering tensile
failure of coupler,
We know that Area resisting tearing

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 EME Paper Solution MK4I
Summer 2022

b) Select a suitable diameter for a solid shaft to iii. Radial & Bursting Pressure on nut is
transmit 200 kW. at 180 rpm. The allowable shear minimum.
stress is 80 N/mm2. iv. Low friction
Ans: Demerits / Disadvantages:
Given: i. Difficult to manufacture.
P= 200 kW= 200 x 103 W ii. Less strong than ACME threads.
N= 180 rpm iii. Screw requires replacement.
τ = 80 N/mm2 iv. More cost.
Find:
d=? Acme or Trapezoidal Thread:

P)
Solution:

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R
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T= 10,615.71 N-m
T= 10615.71 x 103 N-mm

A
An acme or trapezoidal thread, as shown in Fig., is a
t( modification of square thread. The slight slope given
to its sides lowers the efficiency slightly than square
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d3= 676159.87 thread and it also introduces some bursting pressure
d=87.77 mm on the nut, but increases its area in shear.
d= 88 mm Merits / Advantages:
D

i. Easy to manufacture.
c) Explain different forms of threads with their ii. More strong than Square threads.
s

relative advantages and applications. iii. Split type nuts can be used to compensate for
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Ans: wear & tear.

Square Thread: Demerits / Disadvantages:
on

i. Efficiency is less than square threads.

ii. Radial & Bursting Pressure on nut affects the
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performance.
iii. The axial wear at the thread surface can be
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compensated by means of a split-type nut.

Buttress Thread:
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A square thread, as shown in Fig., is adapted

for the transmission of power in either
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direction. This thread Results in maximum

efficiency and minimum radial or bursting
pressure on the nut.
Merits / Advantages:
i. Transmission of power in both
directions.
ii. Higher Efficiency. A buttress thread, as shown in Fig., is used
when large forces act along the screw axis in

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 EME Paper Solution MK4I
Summer 2022

one direction only. This thread combines the Following Stresses may be induced in
higher efficiency of square thread and the Helical spring
ease of cutting and the adaptability to a split i. Pure Torsional
nut of acme thread. It is stronger than other ii. Direct Shear Stress
threads because of greater thickness at the
iii. Combined Torsional, Direct and
base of the thread. The buttress thread has
limited use for power transmission. It is Curvature Shear Stresses
employed as the thread for light jack screws Torsional Shear Stress
and vices.
Merits / Advantages:

P)
i. Higher Efficiency.
ii. Easy to manufacture. Direct Shear Stress:
iii. The axial wear at the thread surface

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can be compensated by means of a

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split-type nut.
iv. More strong than Square threads.

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Demerits / Disadvantages: Combined Torsional & Direct Stress:
i. Transmission of power in one

A
direction only.

d) Find the required diameter of steel rod that has to

carry an axial pull of 40 kN, if the permissible stress
t( Due to Curvature Shear Stress:
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is 150 MPa.
Ans:
D

Given:
P= 40 kN= 40 x 103 N D = Mean diameter of the spring coil,
s

σ= 150 MPa = 150 N/mm2 d = Diameter of the spring wire,

Find: n = Number of active coils,
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d=? G = Modulus of rigidity for the spring

on

Solution: material,
P = Axial load on the spring,
τ1 = Maximum shear stress induced in the
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wire,
C = Spring index = D/d,
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p = Pitch of the coils, and

δ = Deflection of the spring, due to an axial
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load P

4. Attempt any THREE of the following: 12

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d2 = 339.70
d= 18.43 mm a) Explain following types of stresses.
Take i) Transverse shear stress ii) Compressive stress
d= 20 mm Ans:
i) Transverse shear stress:
e) Explain various stresses induced in helical Transverse shear stress is the resistance force
compression spring. developed per unit cross-sectional area by an object
Ans: to avoid transverse shear deformation (splitting of the

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 EME Paper Solution MK4I
Summer 2022

layers). It arises due to the application of bending

It takes less time than Time-consuming
load. riveting. process.

Inspection is very Easier to inspect.

difficult.

c) Define following terms with reference to

compression spring: i) Solid length ii) Free length
iii) Spring index iv) Spring rate (Spring stiffness)
Ans:
i) Solid length: When the compression spring is

P)
ii) Compressive stress:
compressed until the coils come in contact with each
Compressive Stress can be defined as the force which
other, then the spring is said to be solid. The solid

K
acts per unit area.
length of a spring is the product of the total number of

R
coils and the diameter of the wire.

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LS = n'd
b) Differentiate between welded joint and riveted where LS= Solid Length

A
joint. n' = Total number of coils, and
Ans: d = Diameter of the wire.
Welded Joint Riveted Joint
t( ii) Free length: The free length of a compression
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Permanent metal joining Semi-permanent joint spring, as shown in Fig., is the length of the spring in
process. the free or unloaded condition.
D

It is rigid joint It is not rigid joint LF= n'.d + δmax+ 0.15 δmax
s

It is stronger Joint. It is weaker than welded

iii) Spring index: The spring index is defined as the
joints.
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ratio of the mean diameter of the coil to the diameter

No connecting Connecting components of the wire.
on

component used. like gusset plate used. C=D/d

Where,
it is lighter. It is heavier.
D = Mean diameter of the coil, and
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Welding can do on any Riveting required d = Diameter of the wire.

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part of the structure. enough clearance

between them. iv) Spring rate (Spring stiffness): The spring rate (or
stiffness or spring constant) is defined as the load
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Thermal expansion may It provides a tolerance

required per unit deflection of the spring.
cause new internal stress to avoid the problem of
in the weld joint. thermal expansion. k=W/δ
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where,
Welding can be done Riveting is not possible W = Load, and
even if only one face of if we can't access both δ = Deflection of the spring
the structure. E.g. Pipes sides.
d) A solid circular shaft of 110 mm diameter is
Heating involved in No heating involved. transmitting power 110 kW at 150 rpm. Find the
welding.
intensity of the induced shear stress in the shaft.
Alteration is very easy. Alteration is not easier. Ans:

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 EME Paper Solution MK4I
Summer 2022

Given:
d= 110 mm
P= 110 kW= 110 x 103 W
N= 150 rpm
Find:
σ=?
Solution:
Since we know,

The two flanges are connected together by means of

P)
3
110 x 10 =
2 𝑥 3.14 𝑥150 𝑥 𝑇 four or six pins. At one end, the pin is fixed to the
60
output flange by means of a nut. The diameter of the

K
3
T=
110 𝑥 10 𝑥 60 pin is enlarged in the input flange where a rubber
2 𝑥 3.14𝑥 150

R
bush is mounted over the pin. The rubber bush is
T= 7,006.36 N-m provided with brass lining at the inner surface. The

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T= 7,006.36 x 103 N-mm lining reduces the wear of the inner surface of the
rubber bush. Power is transmitted from the input shaft
We also know that,

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to the input flange through the key. It is then
transmitted from the input flange to the pin through

7006.36 x 103 = 3.14/16 x 1103 x τ

t( the rubber bush. The pin then transmits the power to
the output flange by shear resistance. Finally, power
ep
3
7006.36 𝑥 10 𝑥 16 is transmitted from the output flange to the output
τ=
3.14𝑥 110
3
shaft through the key.
D

τ = 26.82 N/mm2
b) Explain design procedure of hand lever with neat
sketch.
s

e) Design a knuckle joint to transmit 120 kN. The

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design stresses may be taken as 60 MPa in tension, Ans: ------- Skipped -------
60 MPa in shear and 150 MPa in compression.
on

Ans: c) Explain selection procedure of helical

------Solved in Note Book -------------- compression spring from manufacturer's catalogue.
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5. Attempt any TWO of the following: 12 Ans:Based on functional specifications generate a

first conceptual sketch. Incorporate any restrictions
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a) Explain working of flexible coupling with neat imposed, including maximum outer coil diameter,
sketch. minimum inner coil diameter, limits on free length or
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solid length, or limits on operating displacements.

Ans:The construction of the flexible coupling is
i. Identify potential failure modes.
shown in figure. It is similar to the rigid type of
ii. Select a tentative spring material.
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flange coupling except for the provision of rubber

iii. Select an appropriate design safety factor.
bush and pins in place of bolts. The coupling consists
iv. Calculate the design stress σd.
of two flanges, one keyed to the input shaft and the
other to the output shaft.

v. Determine wire diameter, d, mean coil

radius, R, and number of active coils, N,
it should satisfy strength, life, and spring

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 EME Paper Solution MK4I
Summer 2022

rate. If design performance specifications

are not met, change d, R, and/or N,, until
specifications are satisfied.
vi. Using the tentative values of d, R, and N,
determine spring rate, k, and check to
assure that it also meets any other
functional requirements for k.
vii. Select an appropriate end configuration
and determine the number of inactive
coils. Calculate total number of coils in

P)
the spring.
viii. Determine solid height, free height, and
operational deflection to make sure that

K
no design requirements are violated.

R
6. Attempt any TWO of the following: 12

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a) Design single cotter joint to transmit 200 kN.
Allowable stresses for the material are 75 MPa in

A
tension and 50 MPa in shear.
Ans: ------Solved in Note Book -------
b) Explain selection procedure of ball bearings from
t(
ep
manufacturer's catalogue.
D
s
ic
on
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ha
ec
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Ans:
c) Explain steps involved in a general design
procedure of machine element.
Ans: