HALDIA INSTITUTE OF TECHNOLOGY

Department of Mechanical Engineering

Question Bank
Machine Design
(PC-ME 603)
Session: 2022-23
 Exercise 1

Multiple choice questions

i. The life of a ball bearing is inversely proportional to
(a) (Load)3.33 (b) (Load)3 (c) (Load)2 (d) (Load)1/3

ii. The bearing characteristics number (BCN) relating oil viscosity (Z ), Journal speed (N ) and
bearing pressure (p) is given by
𝑍 𝑍𝑁 𝑍𝑝 𝑝
(a) (b) (c) (d)
𝑝𝑁 𝑝 𝑁 𝑍𝑁

iii. In order to find the maximum bending moment on the arms of a flywheel, it is assumed as a
(a) Simply supported supported beam carrying a uniformly distributed load over the arm

(b) both ends (i.e. at the hub and at the free end of the rim) and carrying a uniformly
distributed load over the arm.

(c) Cantilever beam fixed at the hub and carrying a concentrated load at the free end of the
rim.

(d) None of these.

iv. Autofrettage is a term associated with

(a) Cast iron pressure vessel subjected to external pressure
(b) Low pressure vessels subjected to external pressure
(c) Low pressure spherical vessels
(d) Pre-stressing of thick cylindrical vessels under internal pressure
v. If Z is the actual number of teeth in transverse plane of a helical gear and Ψ is the helix angle,
then the formative number of teeth is given by
(a) Z sec3ψ (b) Z cos ψ (c) Z/ sec3ψ (d) Z cos2ψ
vi. Worm gears are employed for transmission of power between
(a) parallel shafts b) intersecting shafts c) non-parallel and non-intersecting shafts
d) none of these.
vii. Friction radius for a new clutch compared to worn out will be
(a) Same (b) More (c) Less (d) Depends on overall size of clutch.
viii. A multi-disc clutch has three discs on the driving shaft and two discs on the driven shaft. Number
of pair of contact surfaces is
(a) 2 (b)3 (c) 4 (d) 5
 Haldia Institute of Technology
Department of Mechanical Engineering
Machine Design (PC-ME 603)
ix. For a block brake, the equivalent co-efficient of friction is equal to
(a) 4 μ sin θ / (2 θ + sin 2θ) (b) 2 μ sin θ / (2 θ + sin 2θ)
(c) 4 μ sin 2θ / (2 θ + sin 2θ) (d) 2 μ sin θ / (4 θ + sin 2θ)
x. A pressure vessel is said to be thin if the ratio of wall thickness of the shell to its internal diameter
is (a) equal to 1/15 (b) less than 1/15
(c) more than 1/15 (d) none of these
xi. The clutch is used for
(a) connecting two shafts permanently
(b) connecting driver and driven shaft intermittently
(c) engagement and disengagement of driver and driven shaft according to requirement
(d) none of these
xii. The pressure variation in long shoe brakes is proportional to
(a) the distance of the point of contact from the hinge
(b) Sin θ
(c) Cos θ
(d) None of these
xiii. The brake is said to be self-energizing if
(a) The direction of applied force is the same as that of the frictional force
(b) The direction of moment due to frictional force and that due to external force is the same,
required to operate the brake
(c) No external force is required to operate the brake
(d) An external force is required to disengage the brake
xiv. Spur gears are used for
(a) Connecting two skew shafts (b) Connecting intersecting shafts
(c) Transmitting power from one shaft to another shaft
(d) connecting two parallel shafts to transmit power.
xv. Coefficient of fluctuation of speed Ks is
(a) difference between maximum speed and minimum speed
(b) 2(ω1 – ω2)/ (ω1 + ω2)
(c) (ω1 + ω2)/ 2(ω1 - ω2)
(d) (ω1 – ω2)/ 2
xvi. Deep groove ball bearings are used for
(a) heavy thrust load only (b) small angular displacements of shafts
(c) radial load at high speed (d) combined thrust and radial loads at high speed.
xvii. In a centrifugal clutch, the force with which the shoes press against the rim surface of the driver
member is
a) the summation of centrifugal force and spring force

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 Haldia Institute of Technology
Department of Mechanical Engineering
Machine Design (PC-ME 603)
b) the difference between the centrifugal force and spring force
c) the centrifugal force alone
d) the spring force alone.
xviii. The product of the diametral pitch and circular pitch of a gear is equal to
(a) 1 (b) 1/π (c) π (d) π × No. of teeth
xix. Worm gears are employed for transmission of power between
a) parallel shafts b) intersecting shafts c) non-parallel and non-intersecting shafts
d) none of these.
xx. The designation M 33 × 2 of a bolt means
(a) metric threads of 33 Nos. in 2 cm
(b) metric threads with cross-section of 33 mm2
(c) metric threads of 33 pitch diameter and 2 mm pitch
(d) bolt of 33mm nominal diameter having 2 threads per cm.
xxi. If E = kinetic energy of flywheel, Cs = coefficient of fluctuation of speed and ∆E = maximum
fluctuation of energy, then
(a) ∆E = 2ECs (b) ∆E = 2E/Cs (c) ∆E = ECs (d) ∆E = E2/Cs.
xxii. According to uniform wear theory the mean radius of the friction surface of a disc clutch is
(
2 r13 − r23 ) (r1 + r2 )
( )
a) , b) ,
3 r12 − r22 2

(r1 − r2 ) (
2 r13 + r23 )
( )
c) , d)
2 3 r12 − r22
xxiii. Brakes are used
a) to control the motion of a moving body, b) to stop the motion of a moving body,
c) to retard the motion of a moving body, d) all of these.
xxiv. If both the pinion and gear are made of same material then load carrying capacity is decided by
a) Gear b) Pinion
c) None of these d) Both (a) and (b)
xxv. For thick cylindrical pressure vessel Lame’s equation is applicable for
a) Ductile material, b) Brittle material,
c) For both materials, d) None of these

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 Exercise 2

Design of Clutch: Based on Module 1

1. Derive the expression of total frictional torque of ‘Disc clutch’ and ‘Cone clutch’ using

a. Uniform pressure theory and

b. Uniform wear theory

2. State the advantages and disadvantages of a cone clutch.

3. A centrifugal clutch consisting of four shoes transmits 20kW at 760 rpm. The clutch is required to
be engaged at 500 rpm. The inner radius of the drum is 160 mm. The radius of the centre of
gravity of the shoes in engaged position is 135 mm. Assuming coefficient of friction as 0.25
determine mass of each shoe.

4. A cone clutch is to be designed to transmit 7.5 kW at 900 rpm. The cone has a face angle of 12˚.
The width of the face is half of the mean radius and normal pressure between the contact faces is
not to exceed 0.09 N/mm2. Assuming uniform wear and the coefficient of friction between the
contact faces as 0.2, find

i. Mean radius of the friction surface

ii. Width of the friction surface

iii. Outer and inner radius of the friction surface.

5. A cone clutch with asbestos friction lining transmits 25 kW at 600 rpm. The coefficient of friction
is 0.25 and the maximum intensity of pressure is 0.25 N/mm2. The semi-cone angle is 12.5˚. The
outer diameter of friction lining is 250 mm. Considering uniform wear theory, determine

i. The inner diameter of friction lining

ii. The face width of friction lining and

iii. The force required to engage the clutch.

6. A centrifugal clutch consists of 4 shoes. Each shoe has a mass of 1.6 kg and subtends an angle of
45˚ at the centre of rotation, in the engaged position the distance of C.G of the shoes from the axis
is 112 mm. the inner radius of the pulley rim is 145 mm. the shoes are lined with bonded asbestos
woven with fine brass wire having µ = 0.25 and allowable design pressure, p = 0.1 N/mm 2. The
pre-load in the spring is adjusted such that the spring force at the beginning of the engagement is
700 N. The running speed is 1440 rpm. Determine
 Haldia Institute of Technology
Department of Mechanical Engineering
Machine Design (PC-ME 603)
i. The speed at which the engagement begins

ii. Size of each shoe

iii. The power transmitted by the clutch at 1440 rpm.

7. A single plate clutch of an automobile transmits a 300 N-m torque at 1500 rpm. The normal force
on the friction surface exerted by 9 helical compression springs is 3900 N, so that the clutch is
always engaged. The clutch is disengaged when an external force further compresses the spring.
The spring index is 5 and the number of acting coils in each spring is 6. The springs are made of a
material for which G = 81370 N/mm2 and Su = 1540 N/mm2. Permissible shear stress for the
spring is 30% of the ultimate tensile strength. Design the springs and specify their dimensions.

8. A multiple disc clutch steel on bronze is to transmit 4.5 kW at 750 rpm. The inner radius of the
contact is 40 mm and outer radius of the contact is 70 mm. The clutch operates in oil with an
expected coefficient of 0.1. The average allowable pressure is 0.35 N/mm2. Find the following

i. The total number of steel and bronze discs

ii. The actual force required

iii. The actual average pressure

iv. The actual maximum pressure.

9. A plate clutch having a single driving plate with contact surfaces on each side is required to
transmit 110 kW at 1250 r.p.m. The outer diameter of the contact surfaces is to be 300 mm.
The coefficient of friction is 0.4.

i. Assuming a uniform pressure of 0.17 N/mm2; determine the inner diameter of the
friction surfaces.

ii. Assuming the same dimensions and the same total axial thrust, determine the
maximum torque that can be transmitted and the maximum intensity of pressure when
uniform wear conditions have been rached.

10. A cone clutch is used to connect an electric motor running at 1440 rpm with a machine that is
stationary. The machine is equivalent to a rotor of mass 150 kg and radius of gyration as 250
mm. The machine has to be brought to the full speed of 1440 rpm from a stationary condition
in 40 seconds. The semi-cone angle α is 12·5˚. The mean radius of the clutch is twice the face
width. The coefficient of friction is 0·2 and the normal intensity of pressure between
contacting surfaces should not exceed 0·1 N/mm2 Assuming uniform wear.

Calculate

i. the inner and the outer diameters

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 Haldia Institute of Technology
Department of Mechanical Engineering
Machine Design (PC-ME 603)
ii. the face width of the friction lining

iii. the force required to engage the clutch

iv. the amount of heat generated during each engagement of clutch.

11. A single dry plate clutch is to be designed to transmit 7.5 kW at 900 rpm. Find

i. Diameter of the shaft

ii. Mean radius and face width of the friction lining assuming the ratio of the mean
radius to the face width as 4

iii. Outer and inner radii of the clutch plate, and

iv. Dimensions of t spring, assuming that the number of springs are 6 and spring index =
6. The allowable shear stress for the spring wire may be taken as 420 MPa.

12. A multiple disc clutch steel on bronze, is to transmit 4.5 kW at 750 rpm. The inner radius of
the contact is 40 mm and outer radius of the contact is 70 mm. the clutch operates in oil with
an expected coefficient of friction of 0.1. The average allowable pressure is 0.35 N/m2. Find

i. The total number of steel and bronze discs

ii. The actual axial force required

iii. The actual average pressure

iv. The actual maximum pressure.

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 Exercise 3

Design of Brakes: Based on Module 2

1. Explain the following

i. Self energizing brake

ii. Self locking brake

4 𝑠𝑖𝑛𝜃
2. For long shoe brake show that the value of equivalent coefficient of friction is 𝜇′ = 𝜇 [2𝜃+sin 2𝜃]

3. The block brake as shown in figure 1 provides a breaking torque of 360 N-m. The diameter of the
brake drum is 300 mm. The coefficient of friction is 0.3. Find:

i. The force (P) to be applied at the end of the lever for the CW and CCW rotation of the brake
drum.

ii. The location of the pivot or fulcrum to make the brake self locking for the CW rotation of the
brake drum.

Figure 1

4. A rope drum of an elevator having 650 mm diameter is fitted with a brake drum of 1 m diameter.
The brake drum is pivoted with four cast iron brake shoes each subtending an angle of 45˚. The
mass of the elevator when loaded is2000 kg and moves with a speed of 2.5 m/s. the brake has a
sufficient capacity to stop the elevator in 2.75 m. Assuming the coefficient of friction between the
brake drum and shoes as 0.2, find

i. Width of the shoe, if the allowable pressure on the brake shoe is limited to 0.3 N/mm2

ii. Heat generated in stopping the elevator.

5. A double shoe brake as shown in figure2 is capable of absorbing a torque of 1400 N-m. The
diameter of the brake drum is 350 mm and the angle of contact for each shoe is 100˚. If the
coefficient of friction between the brake drum and lining is 0.4; find:
 Haldia Institute of Technology
Department of Mechanical Engineering
Machine Design (PC-ME 603)
i. The spring force necessary to set the brake

ii. The width of the brake shoes, if the bearing pressure on the lining material is not to exceed 0.3
N/mm2.

Figure 2

6. A double block brake is shown in figure 3. The brake drum rotates in a CW direction and the
actuating force is 500N. The coefficient of friction between the blocks and the drum is 0.35.
Calculate the torque absorbing capacity of the brake.

Figure 3

7. An automotive type internal expanding double-shoe brake is shown in figure 4. The face width of
the friction lining is 40mm and the maximum intensity of normal pressure is limited to 1 N/mm 2.
The coefficient of friction is 0.32. The angle θ1 can be assumed to be zero. Calculate:

i. The actuating force P

ii. The torque absorbing capacity of the brake.

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 Haldia Institute of Technology
Department of Mechanical Engineering
Machine Design (PC-ME 603)

Figure 4 Figure 5
8. A differential band brake as shown in figure 5, has an angle of contact of 225˚. The band has a
compressed woven lining and bears against a cast iron drum of 350 mm diameter. The brake is to
sustain a torque of 350 N-m and the coefficient of friction between the band and the drum is 0.3.
Find:

i. The necessary force (P) for the CW and CCW rotation of the drum

ii. The value of ‘OA’ for the brake to be self locking, when the drum rotates CW.

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 Exercise 4

Design of Spur, Helical, Bevel Gears, and

Worm-worm wheels: Based on Module 3
1. Explain the advantage of involute gear tooth profile.

2. What do you mean by interference and undercut in gear teeth?

3. Design a pair of helical gears when the pinion running at 1450 r.p.m. transmits 30 kW at medium
shocks to a gear running at 400 r.p.m. Given that the ultimate limit for the material of the gear and
the pinion is 500 MPa and the young’s modulus is 200 GPa. Use a helix angle of 15˚ and a 20˚
involute full depth profile. Check for hardness (BHN) in relation to endurance and wear strength
when the margin of safety should be at least 75% of the dynamic load.

4. Design a spur gear drive transmitting 30 kW at 400 rpm to another shaft running approximately at
100 rpm. The load is steady and continuous. The material for the pinion and gear are made of cast
steel and cast iron respectively. Take module as 10 mm. also check the design for dynamic load
and wear. Assume the allowable static stress for pinion and gear as 140 MPa and 56 MPa
respectively. Number of teeth for the pinion is 24. The tooth form factor is given by the
expression: y = 0.154 – (0.912/No. of teeth) and the velocity factor Cv = 3/ (3 + v), where, v is the
peripheral speed in m/s. The flexural endurance limits for cast iron and cast steel are given as 84
MPa and 252 MPa respectively. Surface endurance limit is given as 630 MPa. Tooth error in
action = 0.023 mm. The Young’s modulii for pinion and gear are 0.2 ×106 MPa and 0.1 × 106
MPa respectively. Also assume the starting torque to be 25% higher than the running torque.

5. A bronze spur pinion rotating at 600 r.p.m. drives a cast iron spur gear at a transmission ratio of
4:1. The allowable static stresses for the bronze pinion and cast iron gear are 84 MPa and 105
MPa respectively. The pinion has 16 standard 20˚ full depth involute teeth of module 8 mm. The
face width of both the gears is 90 mm. Find the power that can be transmitted from the standpoint
of strength. Given Lewis form factor = 0.154 – (0.912/T) and Cv = 3/(3+ v).

6. Two spur gears have a velocity ratio of 1/3. The driven gear has 72 teeth of 8 mm module and
rotates at 300 rpm. Calculate the number of teeth and the speed of the driver. What will be the
pitch line velocities?

7. A pair of straight teeth spur ears, having 20˚ full depth involute teeth is to transmit 12 kW at 300
r.p.m of the pinion. The speed ratio is 3:1. The allowable static stress for gear of cast iron and
pinion of steel are 60 MPa and 105 MPa respectively. Assuming the following:
 Haldia Institute of Technology
Department of Mechanical Engineering
Machine Design (ME 603)
Number of teeth of pinion = 16; Face width = 14 times of module; Cv = 4.5/(4.5+v); and y =
0.154 – (0.912/T).

Determine the module, face width and pitch diameter of gear. Check the gears for wear; Given σ es
= 600 MPa; EP = 200 kN/mm2 and EG = 100 kN/mm2.

8. Determine the shaft power which can be transmitted by a pair of helical gears, 20˚ full
depth, 25˚ helix, having a normal module of 5 mm. Both the gears are made of forged C-
30 steel and have a face width of 76.2 mm. The pinion speed is 2000 rev/min and it has
20 teeth. The velocity ratio to be 5 to 1.
9. A pair of spur gears with 20˚ full-depth involute teeth consists of a 19 teeth pinion
meshing with a 40 teeth gear. The pinion is mounted on a crank shaft of 7.5 kW single
cylinder diesel engine running at 1500 rpm. The driven shaft is connected to a two stage
compressor. Assume the service factor as 1.5. The pinion as well as the gear is made of
steel 40C8 (Sut = 600 N/mm2) the module and the face width of the gears are 4 &40 mm
respectively
i. Using the velocity factor to account for the dynamic load, determine the factor of
safety.
ii. If the factor of safety is 2 for pitting failure, recommend surface hardness for the
gears.
iii. If the gears are machined to meet the specification of grade 8, determine the
factor of safety for bending using Buckinghum’s equations.
iv. Is the gear design satisfactory? If not, what is the method to satisfy the design
conditions? How will you modify the design?
10. A pair of parallel helical gears consists of 24 teeth pinion rotating at 5000 rpm &
supplying 2.45 kW power to the gear. The speed reduction is 4:1. The normal pressure
angle and helix angle are 20˚ & 23˚ respectively. Both gears are made of hardened steel
(Sut = 750 N/mm2). The service factor & the factor of safety are 1.5 & 2 respectively.
The gears are finished to meet the accuracy of grade-4.
i. In the initial stages of gear design , assume that the velocity factor accounts for
the dynamic load and that the face width is 10 times the normal module.
Assuming the pitch line velocity to be 10 m/s, estimate the normal module.
ii. Select the first preference value of the normal module & calculate the main
dimensions of the gears.

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 Haldia Institute of Technology
Department of Mechanical Engineering
Machine Design (ME 603)
iii. Determine the dynamic load using Buckinghum’s equations & find out the
effective load for the above dimensions. What is the correct factor of safety for
bending?
iv. Specify surface hardness for the gears, assuming a factor of safety of 2 for wear
consideration.
11. A gear drive is required to transmit a maximum power of 22.5 kW. The velocity ratio is
1:2 & rpm of the pinion is 200. The approximate centre distance between the shafts may
be taken as 600 mm. the teeth has 20˚ stub-involute profiles. The static stress for the gear
material may be taken as 60 MPa & face width as 10 times the module. Find the module,
face width & number of teeth on each gear. Check the design for dynamic and wear
loads. The deformation or dynamic factor in the Buckinghum’s equations may be taken
as 80 and the material combination factor for the wear as 1.4.
12. A pair of straight teeth spur gear, having 20˚ involute full depth teeth is to transmit 12
kW at 300 rpm of the pinion. The speed ratio is 3:1. The allowable static stresses for gear
of cast iron & pinion of steel are 60 MPa and 105 MPa respectively. Assume the
following:
No. of teeth of pinion = 16, Face with = 14 times of module, Velocity factor Cv = 4.5/
(4.5 + v), v being the pitch line velocity in m/s and tooth form factor y = 0.154 –
(0.912/No. of teeth).
Determine the module, Face width and Pitch diameters of gears. Check the gears for
wear, given es = 600 MPa, EP = 200 kN/mm2 & EG = 100 kN/mm2.
13. A pair of helical gears are to transmit 15 kW. The teeth are 20˚ stub in diametral plane
and have a helix angle of 45˚. The pinion runs at 10000 rpm and has 80 mm pitch
diameter. The gear has 320 mm pitch diameters. If the gears are made of cast steel
having allowable static strength of 100 MPa, determine a suitable module & face width
from static strength considerations & check the gears for wear. Given es = 618 MPa.
14. A helical cast steel gear with 30˚ helix angle has to transmit 35 kW at 1500 rpm. If the
gear has 24 teeth, determine the necessary module, pitch diameter & face width for 20˚
full depth teeth. The static stress for cast steel may be taken as 56 MPa. The width of
face may be taken as 3 times the normal pitch. What would be the end thrust on the gear?
The tooth factor for 20˚ full depth involute gear may be taken as 0.154- (0.912/ TE),
where TE represents the equivalent no. of teeth.

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 Haldia Institute of Technology
Department of Mechanical Engineering
Machine Design (ME 603)
15. Explain why worm gear reduction units are not preferred over other types of gear boxes for
transmitting large power. What are the materials for worm and worm wheel? Explain why
dissimilar materials are used for manufacturing worm and worm wheel?

16. A pair of worm gear is designed as 2/54/10/5. Calculate:

i. Reduction ratio

ii. Pitch diameter of worm and worm wheel

iii. Centre distance.

17. A pair of 20˚ full depth involute teeth bevel gears connects two shafts at right angle having
velocity ratio 3:1. The gear is made of cast steel having allowable static stress as 70 MPa and the
pinion is of steel with allowable static stress as 100 MPa. The pinion transmits 37.5 kW at 750
r.p.m. Determine:

i. Module and face width

ii. Pitch diameter

iii. Pinion shaft diameter

Assume tooth form factor y = 0.154 – (0.912/TE) where TE is the formative number of teeth, width
is 1/3rd of the length of pitch cone, and pinion shaft overhangs by 150 mm.

18. Two steel bevel gears both having a Brinell Hardness of 250, connect shafts at a 90˚. The teeth are
1
14 ˚ full depth & the module is 5 mm. The number of teeth on the pinion & gear are 30 & 38.
2
The face width is 38 mm. Determine the wear load.

19. A speed reducer unit is to be designed for an input of 0.75 kW with transmission ratio of 27. The
speed of the hardness steel worm is 1750 rpm. The worm wheel is to be made of phosphor bronze.
The tooth form is to be 20˚ involute.

20. A triple threaded worm has teeth of 16 mm module and pitch circle diameter of 60 mm. if the
worm has 30 teeth, find

i. The lead angle

ii. Velocity ratio

iii. Centre distance of worm gearing system.

21. A cast iron bevel gear has a module of 2.5 mm and its pitch diameter is 0.6 m. the pitch angle is
30˚ and the teeth are 20˚ full depth. Determine the permissible endurance load. Assume flexural
endurance limit for cast iron = 84 MPa.

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 Haldia Institute of Technology
Department of Mechanical Engineering
Machine Design (ME 603)
22. Design a speed reducer unit of worm and worm wheel. The worm and gear of 20˚ involute teeth
have to transmit 11.25 kW between shafts which are 0.25 m apart. Speed reduction is to be 10.5 to
1, and the rotation of the driving shaft to be 1200 rpm. Check the design for dynamic load, wear
and heat dissipation.

23. A pair of straight bevel gears is mounted on shafts, which are intersecting at right angles. The
number of teeth on the pinion and gear are 21 & 28 respectively. The pressure angle is 20˚. The
pinion shaft is connected to an electric motor developing 5 kW rated power at 1440 rpm. The
service factor can be taken as 1.5. The pinion and the gear are made of steel (Sut = 750 MPa) and
heat-treated to a surface hardness of 380 BHN. The gears are machined by a manufacturing
process, that limits the error between meshing teeth to 10 μm. The module and face width are 4
mm and 20 mm respectively. Determine the factor of safety for bending as well as pitting.

24. A pair of cast iron bevel gears connect two shafts at right angles. The pitch diameters of the
pinion and gear are 80 mm and 100 mm respectively. The tooth profiles of the gears are of
14 1⁄2˚ composite form. The allowable static stress for both the gears is 55 MPa. If the pinion
transmits 2.75 kW at 1100 rpm, find the module and number of teeth on each gear form the stand-
point of strength and check the design from the stand-point of wear. Take surface endurance limit
as 630 MPa and modulus of elasticity for cast iron as 84 kN/mm2.

25. A speed reducer unit is to be designed for an input of 1.1 kW with a transmission ratio 27. The
speed of the hardened steel worm is 1440 rpm. The worm wheel is to be made of phosphor
bronze. The tooth form is to be 20˚ involute.

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 Exercise 5

Design of Pressure Vessels: Based on

Module 4
1. Obtain the general expressions of three principal stresses i.e., 𝜎𝑟 , 𝜎𝑡 , 𝜎𝑙 for any thick pressure
vessel with outer diameter Do and inner diameter Di.

2. Obtain the expression for thickness of any thick pressure vessel according to Lame’s method and
Clavarino’s method.

3. Obtain the expression of shrinkage pressure for any compound cylinder.

4. Write short note on (a) Autofrettage of thick cylinder, (b) Unfired pressure vessels

5. A high-pressure cylinder consists of a steel tube with inner and outer diameters of 20 and 40mm
respectively. It is jacketed by an outer steel tube, having an outer diameter of 60mm. the tubes are
assembled by a shrinking process in such a way that the maximum principal stress induced in any
tube is limited to 100 MPa. Calculate the shrinkage pressure and original dimensions of the tube.
Take E = 207GPa.

6. A cylindrical closed tank made of plane carbon steel having 𝜎𝑦𝑡 = 350 MPa and 𝜎𝑢𝑡 = 400 MPa.
Poisson’s ratio is 0.26 is of internal diameter 250 mm. the vessel contains a pressurized toxic gas,
the pressure being limited to a maximum value of 16 MPa. Calculate the wall thickness of the
cylinder assuming a factor of safety as high as 5 in view of the criticality of the service.

7. A tube with 50 mm and 75 mm as inner and outer diameters respectively, is reinforced by

shrinking a jacket of outer diameter 100 mm. The compound tube is to withstand an internal
pressure of 35 MPa. The shrinkage allowance is such that the maximum tangential stress in each
tube has same magnitude. Calculate:

i) The shrinkage pressure; and

ii) The original dimensions of tubes.

Show the distribution of tangential stresses. Assume E = 207 kN/mm2.

 Exercise 6

Design of Flywheels: Based on Module 5

1. Design completely the flywheel, the flywheel shaft and the key for securing the flywheel to the
shaft for a punching machine (four stroke) having a capacity for producing 30 holes of 19 mm
diameter/minute in steel plate 16 mm thick, the material of the plate has an ultimate shear stress of
350 MPa and the allowable shear stress for the shaft material is 32 MPa. The actual punching
operation is estimated to last for 1/5 th of the angular rotation of the crank-shaft. The crank-shaft
is powered by a flywheel shaft through a reduction gearing having ratio of 1:10. Assume:

i. Mechanical efficiency of punching machine is 0.75.

ii. During the punching operation the flywheel speed is reduced by a maximum of 10% of the
mean speed.

iii. The space limitations restrict the flywheel diameter to 0.92 m.

2. A machine coupled to a two-stroke engine which produces a torque of (800 +180 sin 3θ) N-m.
Where θ is the crank angle. The engine speed is 400 rpm. The flywheel and other rotating parts
attached to the engine have a mass of 350 Kg at a radius of gyration of 200 mm. calculate the total
fluctuation of speed of the flywheel when the resisting torque is (800 +80 sin 3θ) N-m.

3. A punching machine makes 25 working strokes per minute and is capable of punching 25 mm
diameter holes in 18 mm thick steel plates having an ultimate shear stress of 300 MPa. The
punching operation takes place during 1/10th of a revolution of the crank-shaft. Estimate the
power needed for the driving motor assuming a mechanical efficiency of 95%. Determine the
suitable dimensions for the rim cross-section of the flywheel which is to revolve at 9 times the
speed of the crank-shaft. The permissible coefficient of fluctuation of speed is 0.1. The flywheel
is to be made of cast iron having a working stress of 6 MPa and density of 7250 kg/m 3. The
diameter of the flywheel must not exceed 1.4m owing to space restriction. The hub and spokes
may be assumed to provide 5% of the rotational inertia of the wheel. Check for centrifugal stress
induced in the rim. The width of the flywheel will be taken as 2 times the thickness.

4. The areas of the turning moment diagram for one revolution of a multi-cylinder engine with
reference to the mean turning moment below and above the line are: -32, +408, -267, +333, -310,
+226, -374, +260 and -244 mm2. The scale for abscissa and ordinate are: 1mm = 2.40 and 1mm =
650 N-m respectively. The mean speed is 300 rpm with a percentage speed fluctuation of ± 1.5%.
if the hoop stress in the material of the rim is not to exceed 5.6 MPa, determine the suitable
 Haldia Institute of Technology
Department of Mechanical Engineering
Machine Design (PC-ME 603)
diameter and cross section for the flywheel, assuming that the width is equal to 4 times of the
thickness. The density of the material may be taken as 7200 kg/m3.

5. Design a cast iron flywheel used for a four stroke IC engine developing 180 kW at 240 rpm. The
hoop stress developed in the flywheel is 5.2 MPa, the total fluctuation of speed is to be limited to
3% of the mean speed. The work done during the power stroke is 1/3 more than the average work
done during the whole cycle. The maximum torque on the shaft is twice the mean torque. The
density of cast iron is 7220 kg/m3.

6. A punch press geared 10:1 is to make 8 punches per minute under circumstances where the torque
on the crank shaft is 2.1 kN-m for 0.6 s. The motor nameplate reads 2.6 kW at 1440 rpm for
continuous duty. Design a suitable CI flywheel with solid web and holes in the web around the
middle circle, consider Cs = 0.1 for flywheel. Assume moment of inertia contributed by the rim to
be 90 % of the moment of inertia of the flywheel, width of the rim to be 0.2 times the mean radius
of the flywheel and thickness of the rim to be 0.1 the mean radius of rim.

7. Total fluctuation of speed in a 4-stroke engine is to be limited to 4% of the mean. The engine
produces 112 kW at 150 rpm. Design a CI flywheel if the hoop stress is not to exceed 4 MPa. The
safe shear for the shaft and the key material may be taken as 42 MPa. Assume that the work done
during the power stroke is 1.25 times the average work done during the whole cycle and the
maximum torque on the shaft is twice the mean torque. Take the number of arms to be six.
Weight of the arms and hub may be neglected with respect to the weight of the rim. Assume the
rim and elliptical section of the arm. Density of CI = 500 kg/m3.

8. A punching press pierces 35 holes per minute in a plate using 10 kN-m of energy per hole during
each revolution. Each piercing takes 40 % of the time needed to make one revolution. The punch
received power through a gear reduction unit which in turn is fed by a motor driven belt pulley
800 mm diameter and turning at 210 rpm. Find the power of the electric motor if overall
efficiency of the transmission unit is 80%. Design a cast-iron flywheel to be used with the
punching machine for a coefficient of steadiness of 5, if the space consideration limits the
maximum diameter to 1.3 m. Allowable shear stress for shaft material is 50 MPa, allowable
tensile stress for cast iron is 4 MPa and the density of CI is 7200 kg/m3.

9. An otto cycle engine develops 50 kW at 150 rpm with 75 explosions per minute. The change of
speed from the commencement to the end of power stroke must not exceed 0.5% of mean on
either side. Design a suitable rim section having width four times the depth so that the hoop stress
does not exceed 4 MPa. Assume that the flywheel stores 16/15 times the energy stored by the rim
and the workdone during the power stroke is 1.4 times the workdone during the cycle. Density of
the material is 7200 kg/m3.

22 | Q u e s t i o n B a n k
 Haldia Institute of Technology
Department of Mechanical Engineering
Machine Design (PC-ME 603)
10. A single cylinder double acting steam engine develops 150 kW at a mean speed of 80 rpm. The
coefficient of fluctuation of energy is 0.1 and the fluctuation of speed is ±2% of mean speed. If th
mean diameter of the flywheel rim is 2 metres and the hub and spoke provide 5% of the rotational
inertia of the flywheel, find the mass of the flywheel and cross-sectional area of the rim. Assume
the density of the flywheel material as 7200 kg/m3.

23 | Q u e s t i o n B a n k
 Exercise 7

Design of Bearings: Based on Module 6 & 7

1. Explain the mechanism of pressure development in a hydrodynamic bearing. Draw and explain
Stribeck curve for sliding contact bearings.

2. Define static load capacity of rolling contact bearings. How does it differ from dynamic load
capacity? State and explain Stribeck equation.

3. Under what load conditions a taper roller bearing is recommended?

4. A taper roller bearing has a dynamic load capacity of 30 kN. The desired life of 90% bearing is
10000 hrs and the speed is 1000 rpm. Calculate the equivalent radial load the bearing can carry.

5. How do you express the life of bearing? What is an average or median life?

6. What is sommerfeld number in bearing lubrication?

7. The journal bearing of a turbine shaft of diameter 300 mm is acted upon by a radial load of 160
kN. The rpm of shaft is 1800. Determine the following:

i. Length of the bearing if the allowable bearing pressure is 1.6 N/mm2.

ii. Amount of heat to be removed by the lubricant per minute if the bearing temperature is 60˚C,
the viscosity of oil at 60˚ is 0.02 kg/m-s, the bearing clearance is 0.25 and end leakage factor
k = 0.002 for l/d ratio 0.75 to 2.8.

8. A full journal bearing of 50 mm diameter and 100 mm long has a bearing pressure of 1.4 MPa.
Speed of journal is 1200 rpm and the ratio of journal diameter to the diametral clearance is 1000.
Bearing is lubricated with oil whose absolute viscosity the operating temperature of 75˚C may be
taken as 0.011 kg/ m-s. Room temperature is 35˚C. Find:

i. Amount of artificial cooling required.

ii. Mass of lubricating oil required if the difference between otlet and inlet temperature of the oil
is 10˚C. Take specific heat of oil as 1085 kJ/kg/˚C and heat dissipation coefficient for the
bearing is 420 W/m2/˚C.

9. A journal bearing is proposed for a centrifugal pump. The diameter of the journal is 0.15m and
the load on it is 40 kN and its speed is 900 rev/min. Complete the design calculation for the
bearing. Assume length as 1.6 times of diameter. Absolute viscosity of oil is 0.018 Ns/m2 at the
operating temperature of 55°C. Ambient temperature of oil is 15.5°C.
 Haldia Institute of Technology
Department of Mechanical Engineering
Machine Design (PC-ME 603)
Calculate also mass of the lubricating oil required for artificial cooling, if rise of temperature of
oil be limited to 10°C. Heat dissipation coefficient is 1232 W/m2/°C.

10. A single row deep groove ball bearing is subjected to a radial load of 8 kN and a thrust load of 3
kN. The diameter of the shaft is 75 mm rotating at 1200 rpm. The bearing selected is 6315 for
which the basic static capacity C0 = 72 kN and the basic dynamic capacity ‘C’ is 112 kN. The
radial load factor and thrust factor X and Y are given below in the table. You are required to
determine the expected rated bearing life.

 Fa   Fa 
 Fa   e  e
   Fr   Fr  e
 C0 
X Y X Y

0.025 1 0 0.56 2.0 0.22

0.040 1 0 0.56 1.8 0.24

0.070 1 0 0.56 1.6 0.27

0.130 1 0 0.56 1.4 0.31

0.250 1 0 0.56 1.2 0.37

0.500 1 0 0.56 1.0 0.44

26 | Q u e s t i o n B a n k