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CHAPTER 5
MACHINE DESIGN

m
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YEAR 2012 TWO MARKS

MCQ 5.1 A fillet welded joint is subjected to transverse loading F as shown in the
figure. Both legs of the fillets are of 10 mm size and the weld length is

tas
30 mm. If the allowable shear stress of the weld is 94 MPa, considering the
minimum throat area of the weld, the maximum allowable transverse load
in kN is
lda

(A) 14.44 (B) 17.92

vi

(C) 19.93 (D) 22.16

A force of 400 N is applied to the brake drum of 0.5 m diameter in a band-

Ci

MCQ 5.2
brake system as shown in the figure, where the wrapping angle is 180c. If the
coefficient of friction between the drum and the band is 0.25, the braking
torque applied, in Nm is
w.
ww

(A) 100.6 (B) 54.4

(C) 22.1 (D) 15.7

MCQ 5.3 A solid circular shaft needs to be designed to transmit a torque of 50 Nm. If
the allowable shear stress of the material is 140 MPa, assuming a factor of
safety of 2, the minimum allowable design diameter is mm is
(A) 8 (B) 16

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PAGE 214 MACHINE DESIGN CHAP 5

(C) 24 (D) 32

YEAR 2011 TWO MARKS

MCQ 5.4 Two identical ball bearings P and Q are operating at loads 30 kN and 45 kN
respectively. The ratio of the life of bearing P to the life of bearing Q is
(A) 81 (B) 27

m
16 8
(C) 9 (D) 3
4 2

.co
YEAR 2010 TWO MARKS

MCQ 5.5 A band brake having band-width of 80 mm, drum diameter of 250 mm,
coefficient of friction of 0.25 and angle of wrap of 270 degrees is required to

in the band is
(A) 1.88
tas
exert a friction torque of 1000 Nm. The maximum tension (in kN) developed

(B) 3.56
lda
(C) 6.12 (D) 11.56

MCQ 5.6 A bracket (shown in figure) is rigidly mounted on wall using four rivets.
Each rivet is 6 mm in diameter and has an effective length of 12 mm.
vi
Ci
w.
ww

Direct shear stress (in MPa) in the most heavily loaded rivet is
(A) 4.4 (B) 8.8
(C) 17.6 (D) 35.2

MCQ 5.7 A lightly loaded full journal bearing has journal diameter of 50 mm, bush
bore of 50.05 mm and bush length of 20 mm. If rotational speed of journal
is 1200 rpm and average viscosity of liquid lubricant is 0.03 Pa s, the power
loss (in W) will be
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CHAP 5 MACHINE DESIGN PAGE 215

(A) 37 (B) 74
(C) 118 (D) 237

YEAR 2009 TWO MARKS

MCQ 5.8 A forged steel link with uniform diameter of 30 mm at the centre is subjected

m
to an axial force that varies from 40 kN in compression to 160 kN in tension.
The tensile (Su), yield (Sy) and corrected endurance (Se) strengths of the
steel material are 600 MPa, 420 MPa and 240 MPa respectively. The factor

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of safety against fatigue endurance as per Soderberg’s criterion is
(A) 1.26 (B) 1.37
(C) 1.45 (D) 2.00

• Common Data For Q.9 and Q.10

tas
A 20c full depth involute spur pinion of 4 mm module and 21 teeth is to
transmit 15 kW at 960 rpm. Its face width is 25 mm.
lda
MCQ 5.9 The tangential force transmitted (in N) is
(A) 3552 (B) 2611
(C) 1776 (D) 1305
vi

MCQ 5.10 Given that the tooth geometry factor is 0.32 and the combined effect of
dynamic load and allied factors intensifying the stress is 1.5; the minimum
allowable stress (in MPa) for the gear material is
Ci

(A) 242.0 (B) 166.5

(C) 121.0 (D) 74.0
w.

YEAR 2008 TWO MARKS

MCQ 5.11 A journal bearing has a shaft diameter of 40 mm and a length of 40 mm. The
shaft is rotating at 20 rad/s and the viscosity of the lubricant is 20 mPa−s
ww

. The clearance is 0.020 mm. The loss of torque due to the viscosity of the
lubricant is approximately.
(A) 0.040 N−m (B) 0.252 N−m
(C) 0.400 N−m (D) 0.652 N−m

MCQ 5.12 A clutch has outer and inner diameters 100 mm and 40 mm respectively.
Assuming a uniform pressure of 2 MPa and coefficient of friction of liner
material is 0.4, the torque carrying capacity of the clutch is
(A) 148 N−m (B) 196 N−m

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PAGE 216 MACHINE DESIGN CHAP 5

(C) 372 N−m (D) 490 N−m

MCQ 5.13 A spur gear has a module of 3 mm, number of teeth 16, a face width of
36 mm and a pressure angle of 20c. It is transmitting a power of 3 kW at
20 rev/s. Taking a velocity factor of 1.5 and a form factor of 0.3, the stress
in the gear tooth is about.
(A) 32 MPa (B) 46 MPa

m
(C) 58 MPa (D) 70 MPa

MCQ 5.14 One tooth of a gear having 4 module and 32 teeth is shown in the figure.

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Assume that the gear tooth and the corresponding tooth space make
equal intercepts on the pitch circumference. The dimensions ‘a ’ and ‘b’,
respectively, are closest to

tas
lda
(A) 6.08 mm, 4 mm (B) 6.48 mm, 4.2 mm
(C) 6.28 mm, 4.3 mm (D) 6.28 mm, 4.1 mm
vi

MCQ 5.15 Match the type of gears with their most appropriate description.
Type of gear
P. Helical
Ci

Q. Spiral Bevel
C. Hypoid
S. Rack and pinion
w.

Description
1. Axes non parallel and non intersecting
2. Axes parallel and teeth are inclined to the axis
ww

3. Axes parallel and teeth are parallel to the axis

4. Axes are perpendicular and intersecting, and teeth are inclined to the
axis.
5. Axes are perpendicular and used for large speed reduction
6. Axes parallel and one of the gears has infinite radius
(A) P-2, Q-4, R-1, S-6 (B) P-1, Q-4, R-5, S-6
(C) P-2, Q-6, R-4, S-2 (D) P-6, Q-3, R-1, S-5

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CHAP 5 MACHINE DESIGN PAGE 217

• Common Data For Q.16 and Q.17

A steel bar of 10 # 50 mm is cantilevered with two M 12 bolts (P and Q) to
support a static load of 4 kN as shown in the figure.

m
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MCQ 5.16 The primary and secondary shear loads on bolt P, respectively, are

MCQ 5.17
(A) 2 kN, 20 kN
(C) 20 kN, 0 kN
tas (B) 20 kN, 2 kN
(D) 0 kN, 20 kN

The resultant shear stress on bolt P is closest to

lda
(A) 132 MPa (B) 159 MPa
(C) 178 MPa (D) 195 MPa

YEAR 2007 ONE MARK

vi

MCQ 5.18 A ball bearing operating at a load F has 8000 hours of life. The life of the
bearing, in hours, when the load is doubled to 2F is
Ci

(A) 8000 (B) 6000

(C) 4000 (D) 1000
w.

YEAR 2007 TWO MARKS

MCQ 5.19 A thin spherical pressure vessel of 200 mm diameter and 1 mm thickness
is subjected to an internal pressure varying form 4 to 8 MPa. Assume that
ww

the yield, ultimate and endurance strength of material are 600, 800 and
400 MPa respectively. The factor of safety as per Goodman’s relation is
(A) 2.0 (B) 1.6
(C) 1.4 (D) 1.2

MCQ 5.20 A natural feed journal bearing of diameter 50 mm and length 50 mm

operating at 20 revolution/ second carries a load of 2 kN. The lubricant used
has a viscosity of 20 mPas. The radial clearance is50 μm . The Sommerfeld
number for the bearing is
(A) 0.062 (B) 0.125
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PAGE 218 MACHINE DESIGN CHAP 5

(C) 0.250 (D) 0.785

MCQ 5.21 A bolted joint is shown below. The maximum shear stress, in MPa in the
bolts at A and B , respectively are

m
.co
tas
lda
(A) 242.6, 42.5 (B) 42.5, 242.6
(C) 42.5, 42.5 (D) 18.75, 343.64

MCQ 5.22 A block-brake shown below has a face width of 300 mm and a mean co-
efficient of friction of 0.25. For an activating force of 400 N, the braking
vi

torque in Nm is
Ci
w.
ww

(A) 30 (B) 40
(C) 45 (D) 60

MCQ 5.23 The piston rod of diameter 20 mm and length 700 mm in a hydraulic cylinder
is subjected to a compressive force of 10 kN due to the internal pressure.
The end conditions for the rod may be assumed as guided at the piston end
and hinged at the other end. The Young’s modulus is 200 GPa. The factor

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CHAP 5 MACHINE DESIGN PAGE 219

of safety for the piston rod is

(A) 0.68 (B) 2.75
(C) 5.62 (D) 11.0

• Common Data For Q.24 and Q.26

m
A gear set has a pinion with 20 teeth and a gear with 40 teeth. The pinion
runs at 30 rev/s and transmits a power of 20 kW. The teeth are on the 20c
full-depth system and have a module of 5 mm. The length of the line of

.co
action is 19 mm.
MCQ 5.24 The center distance for the above gear set in mm is
(A) 140 (B) 150
(C) 160 (D) 170

MCQ 5.25
(A) 1.21
(C) 1.29
tas
The contact ratio of the contacting tooth is
(B) 1.25
(D) 1.33
lda
MCQ 5.26 The resultant force on the contacting gear tooth in N is
(A) 77.23 (B) 212.20
(C) 2258.1 (D) 289.43
vi

YEAR 2006 TWO MARKS

Ci

MCQ 5.27 A disc clutch is required to transmit 5 kW at 2000 rpm. The disk has a
friction lining with coefficient of friction equal to 0.25. Bore radius of friction
lining is equal to 25 mm. Assume uniform contact pressure of 1 MPa. The
value of outside radius of the friction lining is
w.

(A) 39.4 mm (B) 49.5 mm

(C) 97.9 mm (D) 142.9 mm

MCQ 5.28 Twenty degree full depth involute profiled 19 tooth pinion and 37 tooth gear
ww

are in mesh. If the module is 5 mm, the centre distance between the gear
pair will be
(A) 140 mm (B) 150 mm
(C) 280 mm (D) 300 mm

MCQ 5.29 A cylindrical shaft is subjected to an alternating stress of 100 MPa. Fatigue
strength to sustain 1000 cycles is 490 MPa. If the corrected endurance
strength is 70 MPa, estimated shaft life will be
(A) 1071 cycles (B) 15000 cycles

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PAGE 220 MACHINE DESIGN CHAP 5

(C) 281914 cycles (D) 928643 cycles

MCQ 5.30 A 60 mm long and 6 mm thick fillet weld carries a steady load of 15 kN
along the weld. The shear strength of the weld material is equal to 200 MPa
. The factor of safety is
(A) 2.4 (B) 3.4
(C) 4.8 (D) 6.8

m
YEAR 2005 ONE MARK

.co
MCQ 5.31 Which one of the following is criterion in the design of hydrodynamic journal
bearings ?
(A) Sommerfeld number (B) Rating life
(C) Specific dynamic capacity (D) Rotation factor

YEAR 2005

• Common Data For Q.32 and Q.33

tas TWO MARKS
lda
A band brake consists of a lever attached to one end of the band. The other
end of the band is fixed to the ground. The wheel has a radius of 200 mm
and the wrap angle of the band is 270c. The braking force applied to the
lever is limited to 100 N and the coefficient of friction between the band and
vi

the wheel is 0.5. No other information is given.

Ci
w.
ww

MCQ 5.32 The maximum tension that can be generated in the band during braking is
(A) 1200 N (B) 2110 N
(C) 3224 N (D) 4420 N

MCQ 5.33 The maximum wheel torque that can be completely braked is
(A) 200 Nm (B) 382 Nm
(C) 604 Nm (D) 844 Nm

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CHAP 5 MACHINE DESIGN PAGE 221

YEAR 2004 ONE MARK

MCQ 5.34 Two mating spur gears have 40 and 120 teeth respectively. The pinion rotates
at 1200 rpm and transmits a torque of 20 Nm. The torque transmitted by
the gear is
(A) 6.6 Nm (B) 20 Nm
(C) 40 Nm (D) 60 Nm

m
MCQ 5.35 In terms of theoretical stress concentration factor (Kt) and fatigue stress
concentration factor (K f ), the notch sensitivity ‘q ’ is expressed as

.co
(K f − 1) (K f − 1)
(A) (B)
(Kt − 1) (Kt + 1)
(Kt − 1) (K f + 1)
(C) (D)
(K f − 1) (Kt + 1)
MCQ 5.36
(A) 103 cycles
(C) 106 cycles tas
The S-N curve for steel becomes asymptotic nearly at
(B) 10 4 cycles
(D) 109 cycles
lda
YEAR 2004 TWO MARKS

MCQ 5.37 In a bolted joint two members are connected with an axial tightening force
of 2200 N. If the bolt used has metric threads of 4 mm pitch, the torque
vi

required for achieving the tightening force is

Ci

(A) 0.7 Nm (B) 1.0 Nm

w.

(C) 1.4 Nm (D) 2.8 Nm

MCQ 5.38 Match the following

ww

Type of gears Arrangement of shafts

P. Bevel gears 1. Non-parallel off-set shafts
Q. Worm gears 2. Non-parallel intersecting shafts
R. Herringbone gears 3. Non-parallel, non-intersecting shafts
S. Hypoid gears 4. Parallel shafts
(A) P-4 Q-2 R-1 S-3
(B) P-2 Q-3 R-4 S-1
(C) P-3 Q-2 R-1 S-4

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PAGE 222 MACHINE DESIGN CHAP 5

(D) P-1 Q-3 R-4 S-2

YEAR 2003 ONE MARK

MCQ 5.39 A wire rope is designated as 6 # 19 standard hoisting. The numbers 6 # 19

represent
(A) diameter in millimeter # length in meter

m
(B) diameter in centimeter # length in meter
(C) number of strands # numbers of wires in each strand

.co
(D) number of wires in each strand # number of strands

YEAR 2003 TWO MARKS

MCQ 5.40

tas
Square key of side “d/4 ” each and length ‘l ’ is used to transmit torque “T ”
from the shaft of diameter “d ” to the hub of a pulley. Assuming the length
of the key to be equal to the thickness of pulley, the average shear stress
developed in the key is given by
(A) 4T (B) 16T
lda
ld ld 2
(C) 8T2 (D) 16T3
ld πd
MCQ 5.41 In a band brake the ratio of tight side band tension to the tension on the
vi

slack side is 3. If the angle of overlap of band on the drum is 180c, the
coefficient of friction required between drum and the band is
(A) 0.20 (B) 0.25
Ci

(C) 0.30 (D) 0.35

w.

• Common Data For Q.42 and Q.43

The overall gear ratio in a 2 stage speed reduction gear box (with all spur
gears) is 12. The input and output shafts of the gear box are collinear. The
counter shaft which is parallel to the input and output shafts has a gear (
ww

Z2 teeth) and pinion (Z 3 = 15 teeth) to mesh with pinion (Z1 = 16 teeth)

on the input shaft and gear (Z 4 teeth) on the output shaft respectively. It
was decided to use a gear ratio of 4 with 3 module in the first stage and 4
module in the second stage.

MCQ 5.42 Z2 and Z 4 are

(A) 64 and 45 (B) 45 and 64
(C) 48 and 60 (D) 60 and 48

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CHAP 5 MACHINE DESIGN PAGE 223

MCQ 5.43 The centre distance in the second stage is

(A) 90 mm (B) 120 mm
(C) 160 mm (D) 240 mm

YEAR 2002 ONE MARK

m
MCQ 5.44 The minimum number of teeth on the pinion to operate without interference
in standard full height involute teeth gear mechanism with 20c pressure
angle is

.co
(A) 14 (B) 12
(C) 18 (D) 32

YEAR 2002 TWO MARKS

MCQ 5.45
(A) a flange coupling
(B) an Oldham’s coupling
tas
The coupling used to connect two shafts with large angular misalignment is
lda
(C) a flexible bush coupling
(D) a Hooke’s joint

MCQ 5.46 A static load is mounted at the centre of a shaft rotating at uniform angular
velocity. This shaft will be designed for
vi

(A) the maximum compressive stress (static)

(B) the maximum tensile (static)
Ci

(C) the maximum bending moment (static)

(D) fatigue loading

MCQ 5.47 Large speed reductions (greater than 20) in one stage of a gear train are
w.

possible through
(A) spur gearing
(B) worm gearing
ww

(C) bevel gearing

(D) helical gearing

MCQ 5.48 If the wire diameter of a closed coil helical spring subjected to compressive
load is increased from 1 cm to 2 cm, other parameters remaining same, the
deflection will decrease by a factor of
(A) 16 (B) 8
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PAGE 224 MACHINE DESIGN CHAP 5

(C) 4 (D) 2

YEAR 2001 ONE MARK

MCQ 5.49 Bars AB and BC , each of negligible mass, support load P as shown in the
figure. In this arrangement,

m
.co
tas
(A) bar AB is subjected to bending but bar BC is not subjected to bending.
(B) bar AB is not subjected to bending but bar BC is subjected to bending.
lda
(C) neither bar AB nor bar BC is subjected to bending.
(D) both bars AB and BC are subjected to bending.
vi

YEAR 2001 TWO MARKS

MCQ 5.50 Two helical tensile springs of the same material and also having identical
mean coil diameter and weight, have wire diameters d and d/2. The ratio
Ci

of their stiffness is
(A) 1 (B) 4
(C) 64 (D) 128
w.

*********
ww

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CHAP 5 MACHINE DESIGN PAGE 225

SOLUTION

SOL 5.1 Option (C) is correct.

Given : Width of fillets s = 10 mm , l = 30 mm , τ = 94 MPa

m
.co
From figure
tas
The shear strength of the joint for single parallel fillet weld is,
P = Throat Area # Allowable stress
= t#l#τ
t = s sin 45c = 0.707 s
lda
P = 0.707 # s # l # τ
= 0.707 # (0.01) # (0.03) # (94 # 106)
= 19937 N or 19.93 kN
vi

SOL 5.2 Option (B) is correct.

Given : T1 = 400 N, μ = 0.25, θ = 180c = 180c # π = π rad.
Ci

180c
D = 0.5 m, r = D = 0.25 m
2
For the band brake, the limiting ratio of the tension is given by the relation,
T1 = eμθ
w.

T2
400 = e0.25 # π = 2.19
T2
T2 = 400 = 182.68 N
ww

2.19
For Band-drum brake, Braking Torque is
TB = (T1 − T2) # r
= (400 − 182.68) # 0.25 = 54.33 Nm , 54.4 Nm

SOL 5.3 Option (B) is correct.

F.O.S = Allowable shear stress
Design shear stress
Design shear stress for solid circular shaft
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PAGE 226 MACHINE DESIGN CHAP 5

From T = τ
3
τ = 16T3 = 16 # 50 3# 10
πd πd J r

F.O.S = 140 # πd 3
3
Therefore
16 # 50 # 10
2 = 140 # πd 3
3
or,
16 # 50 # 10
3
d 3 = 2 # 16 # 50 # 10

m
140 # π
d = 15.38 mm , 16 mm

.co
SOL 5.4 Option (B) is correct.
Given : WP = 30 kN , WQ = 45 kN
L = b C l # 106 revolutions
k
Life of bearing,
W

For ball bearing, k = 3

So,
W
tas
C = Basic dynamic load rating = Constant

3
L = b C l # 106 revolutions
lda
These are the identical bearings. So for the Life of P and Q.
LP = WQ 3 = 45 3 = 3 3 = 27
c LQ m cWP m b 30 l b2l 8
vi

SOL 5.5 Option (D) is correct.

Given : b = 80 mm , d = 250 mm , μ = 0.25 , θ = 270c, TB = 1000 N−m
Let, T1 " Tension in the tight side of the band (Maximum
Ci

Tension)
T2 " Tension in the slack side of the band (Minimum Tension)
Braking torque on the drum,
w.

TB = (T1 − T2) r
T1 − T2 = TB = 1000 = 8000 N ...(i)
r 0.125
ww

We know that limiting ratio of the tension is given by,

π
T1 = eμθ = ea0.25 # 180 # 270k
= 3.246
T2
T2 = T1
3.246
Substitute T2 in equation (i), we get
T1 − T1 = 8000 & 3.246T1 − T1 = 25968
3.246
2.246T1 = 25968 & T1 = 25968 = 11.56 kN
2.246

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CHAP 5 MACHINE DESIGN PAGE 227

SOL 5.6 Option (B) is correct.

Given : d = 6 mm , l = 12 mm , P = 1000 N
Each rivets have same diameter, So equal Load is carried by each rivet.
Primary or direct force on each rivet,
F = P = 1000 = 250 N
4 4
Shear area of each rivet is,

m
A = π ^6 # 10−3h2 = 28.26 # 10−6 mm2
4
Direct shear stress on each rivet,

.co
τ =F = 250 = 8.84 # 106 - 8.8 MPa
A 28.26 # 10−6

SOL 5.7 Option (A) is correct.

Given : d = 50 mm , D = 50.05 mm , l = 20 mm , N = 1200 rpm , μ = 0.03 Pa s
Tangential velocity of shaft,
tas −3
u = πdN = 3.14 # 50 # 10 # 1200 = 3.14 m/ sec
60 60
y = D − d = 50.05 − 50 = 0.025 mm
lda
And Radial clearance,
2 2
Shear stress from the Newton’s law of viscosity,
τ = μ # u = 0.03 # 3.14 = 3768 N/m2
y 0.025 # 10−3
vi

Shear force on the shaft,

F = τ # A = 3768 # (π # d # l)
= 3768 # 3.14 # 50 # 10−3 # 20 # 10−3 = 11.83 N
Ci

Torque, T = F # d = 11.83 # 50 # 10−3 = 0.2957 N−m

2 2
We know that power loss,
w.

P = 2πNT = 2 # 3.14 # 1200 # 0.2957

60 60
= 37.13 W - 37 W
ww

SOL 5.8 Option (A) is correct.

Given : Su or σu = 600 MPa , Sy or σy = 420 MPa , Se or σe = 240 MPa ,
d = 30 mm Fmax = 160 kN (Tension), Fmin =− 40 kN (Compression)
3
Maximum stress, σmax = Fmax = 160 # 10 = 226.47 MPa
A π (30) 2
4
3
Minimum stress, σmin = Fmin =− 40 # 10 =− 56.62 MPa
A π (30) 2
4#

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PAGE 228 MACHINE DESIGN CHAP 5

Mean stress, σm = σmax + σmin = 226.47 − 56.62 = 84.925 MPa

2 2
226.47 − (− 56.62)
Variable stress, σv = σmax − σmin =
2 2
= 141.545 MPa
From the Soderberg’s criterion,

m
1 = σm + σv
F .S. σy σe
1 = 84.925 + 141.545 = 0.202 + 0.589 = 0.791

.co
F .S. 420 240
So, F.S. = 1 = 1.26
0.791

SOL 5.9 Option (A) is correct.

Pitch circle diameter,

tas
Given : m = 4 mm , Z = 21, P = 15 kW = 15 # 103 W N = 960 rpm
b = 25 mm , φ = 20c
D = mZ = 4 # 21 = 84 mm
Tangential Force is given by,
lda
FT = T ...(i)
r
Power transmitted, P = 2πNT & T = 60P
60 2πN
FT = 60P # 1
vi

Then r = Pitch circle radius

2πN r
3
= 60 # 15 # 10 # 1
2 # 3.14 # 960 42 # 10−3
Ci

= 3554.36 N - 3552 N

SOL 5.10 Option (B) is correct.

w.

From Lewis equation

pd = π = π = 1
F p FT
σb = T d =
by b#y#m pc πm m
ww

= 3552
25 # 10−3 # 0.32 # 4 # 10−3
σb = 111 MPa
Minimum allowable (working stress)
σW = σb # Cv = 111 # 1.5 = 166.5 MPa

SOL 5.11 Option (A) is correct.

Given : d = 40 mm , l = 40 mm , ω = 20 rad/ sec
Z (μ) = 20 mPa − s = 20 # 10−3 Pa − s , c (y) = 0.020 mm

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CHAP 5 MACHINE DESIGN PAGE 229

Shear stress, τ = μu From the Newton’s law of viscosity...(i)

y
u = rω = 0.020 # 20 = 0.4 m/ sec
−3
τ = 20 # 10 # −03.4 = 400 N/m2
0.020 # 10
Shear force is generated due to this shear stress,
F = τ A = τ # πdl A = πdl = Area of shaft

m
= 400 # 3.14 # 0.040 # 0.040 = 2.0096 N
Loss of torque, T = F # r = 2.0096 # 0.020

.co
= 0.040192 N−m - 0.040 N−m

SOL 5.12 Option (B) is correct.

Given : d1 = 100 mm & r1 = 50 mm , d2 = 40 mm & r1 = 20 mm
p = 2 MPa = 2 # 106 Pa , n = 0.4

tas
When the pressure is uniformly distributed over the entire area of the friction
faces, then total frictional torque acting on the friction surface or on the
clutch is given by,
lda
(r ) 3 − (r2) 3
T = 2πμp ; 1 E
3
= 2 # 3.14 # 0.4 # 2 # 106 6(50) 3 − (20) 3@ # 10−9
3
= 195.39 N−m - 196 N−m
vi

SOL 5.13 Option (B) is correct.

Ci

Given : m = 3 mm , Z = 16 , b = 36 mm , φ = 20c, P = 3 kW
N = 20 rev/ sec = 20 # 60 rpm = 1200 rpm , Cv = 1.5 , y = 0.3
Module, m =D
Z
w.

D = m # Z = 3 # 16 = 48 mm
Power, P = 2πNT
60
ww

3
T = 60P = 60 # 3 # 10
2πN 2 # 3.14 # 1200
= 23.88 N−m = 23.88 # 103 N−mm
3
Tangential load, WT = T = 2T = 2 # 23.88 # 10 = 995 N
R D 48
From the lewis equation Bending stress (Beam strength of Gear teeth)
σb = WT Pd = WT π π 1
by bym :Pd = PC = πm = m D

= 995
36 # 10−3 # 0.3 # 3 # 10−3
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PAGE 230 MACHINE DESIGN CHAP 5

σb = 995 = 30.70 # 106 Pa = 30.70 MPa

3.24 # 10−5
Permissible working stress
σW = σb # Cv = 30.70 # 1.5 = 46.06 MPa , 46 MPa

SOL 5.14 Option (D) is correct.

m
.co
We know that,
Pitch circle diameter,
tas
Given : m = 4 , Z = 32 , Tooth space = Tooth thickness = a
m =D
Z
D = mZ = 4 # 32 = 128 mm
lda
And for circular pitch, Pc = πm = 3.14 # 4 = 12.56 mm
We also know that circular pitch,
Pc = Tooth space + Tooth thickness
= a + a = 2a
vi

a = Pc = 12.56 = 6.28 mm
2 2
b = addendum + PR
Ci

From the figure,

PQ a/2 3.14
or sin φ = = =
OQ 64 64
φ = sin−1 (0.049) = 2.81c
w.

OP = 64 cos 2.81c = 63.9 mm

PR = OR − OP = 64 − 63.9 = 0.1 mm
OR = Pitch circle radius
ww

And b = m + PR = 4 + 0.1 = 4.1 mm

Therefore, a = 6.28 mm and b = 4.1 mm

SOL 5.15 Option (A) is correct.

Types of Gear Description
P. Helical 2. Axes parallel and teeth are inclined to the axis
Q. Spiral Bevel 4. Axes are perpendicular and intersecting, and
teeth are inclined to the axis

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CHAP 5 MACHINE DESIGN PAGE 231

R. Hypoid 1. Axes non parallel and non-intersecting

S. Rack and pinion 6. Axes are parallel and one of the gear has infinite
radius
So, correct pairs are P-2, Q-4, R-1, S-6

m
SOL 5.16 Option (A) is correct.

.co
tas
lda
In this figure WS represent the primary shear load whereas WS1 and WS2
represent the secondary shear loads.
Given : A = 10 # 50 mm2 , n = 2 , W = 4 kN = 4 # 103 N
We know that primary shear load on each bolt acting vertically downwards,
vi

Ws = W = 4 kN = 2 kN
n 2
Since both the bolts are at equal distances from the centre of gravity G of
Ci

the two bolts, therefore the secondary shear load on each bolt is same.
For secondary shear load, taking the moment about point G ,
Ws1 # r1 + Ws2 # r2 = W#e
= r2 and Ws1 = Ws2
w.

r1
So, 2r1 Ws1 = 4 # 103 # (1.7 + 0.2 + 0.1)
2 # 0.2 # Ws1 = 4 # 103 # 2
3
Ws1 = 8 # 10 = 20 # 103 = 20 kN
ww

2 # 0.2

SOL 5.17 Option (B) is correct.

From the figure, resultant Force on bolt P is
F = Ws2 − Ws = 20 − 2 = 18 kN
Shear stress on bolt P is,
τ = F = 18 # 103 = 159.23 MPa - 159 MPa
Area π (12 10 −3 2
)
4# #

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PAGE 232 MACHINE DESIGN CHAP 5

SOL 5.18 Option (D) is correct.

Given : W1 = F , W2 = 2F , L1 = 8000 hr
We know that, life of bearing is given by
L = b C l # 106 revolution
k

W
L = b C l # 106 revolution
3
For ball bearing, k = 3 ,
W

m
For initial condition life is,
L1 = bC l # 106
3

.co
8000 hr = bC l # 106
3
...(i)
F
L2 = b C l # 106 = 1 # bC l # 106
3 3
For final load,
2F 8 F

SOL 5.19 Option (B) is correct.

tas
= 1 (8000 hr) = 1000 hr
8

Given : d = 200 mm , t = 1 mm , σu = 800 MPa , σe = 400 MPa

From equation (i)
lda
Circumferential stress induced in spherical pressure vessel is,
p r p 100
σ = # = # = 50p MPa
2t 2#1
Given that, pressure vessel is subject to an internal pressure varying from
vi

4 to 8 MPa.
So, σmin = 50 # 4 = 200 MPa
σmax = 50 # 8 = 400 MPa
Ci

Mean stress, σm = σmin + σmax = 200 + 400 = 300 MPa

2 2
Variable stress, σv = σmax − σmin = 400 − 200 = 100 MPa
w.

2 2
From the Goodman method,
1 = σm + σv = 300 + 100 = 3 + 1 = 5 & F.S. = 8 = 1.6
F .S. σu σe 800 400 8 4 8 5
ww

SOL 5.20 Option (B) is correct.

Given : d = 50 mm , l = 50 mm , N = 20 rps ,
Z = 20 mPa − sec = 20 # 10−3 Pa − sec
Radial clearance = 50 μm = 50 # 10−3 mm , Load = 2 kN
We know that,
p = Bearing Pressure on the projected bearing area
Load on the journal
=
l#d
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CHAP 5 MACHINE DESIGN PAGE 233

3
= 2 # 10 = 0.8 N/mm2 = 0.8 # 106 N/m2
50 # 50
c = diameteral clearance
Sommerfeld Number = ZN b d l
2

p c = 2 # radial clearance
−3 2
S.N. = 20 # 10 #6 20 # b 50
−3 l
0.8 # 10 100 # 10

m
−3
= 20 # 10 #6 20 # b 1 l # 106 = 0.125
2

0.8 # 10 2

.co
SOL 5.21 Option (A) is correct.

tas
vi lda

Given : Diameter of bolt d = 10 mm , F = 10 kN , No. of bolts n = 3

Direct or Primary shear load of each rivet
3
FP = F = 10 # 10 N
Ci

n 3
FP = 3333.33 N
The centre of gravity of the bolt group lies at O (due to symmetry of figure).
e = 150 mm (eccentricity given)
w.

Turning moment produced by the load F due to eccentricity

= F # e = 10 # 103 # 150
= 1500 # 103 N−mm
ww

Secondary shear load on bolts from fig. rA = rC = 40 mm and rB = 0

We know that F # e = FA [(rA) 2 + (rB) 2 + (rC ) 2]
rA
= FA # [2 (rA) 2] (rA = rC and rB = 0 )
rA
1500 # 103 = FA # [2 (40) 2] = 80FA
40
3
FA = 1500 # 10 = 18750 N
80

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PAGE 234 MACHINE DESIGN CHAP 5

FB = 0 (rB = 0)
FC = FA # rC = 18750 # 40
rA 40
= 18750 N
From fig we find that angle between
FA and FP = θA = 90c

m
FB and FP = θB = 90c
FC and FP = θC = 90c
Resultant load on bolt A,

.co
RA = (FP ) 2 + (FA) 2 + 2FP # FA cos θA
= (3333.33) 2 + (18750) 2 + 2 # 3333.33 # 18750 # cos 90c
RA = 19044 N
Maximum shear stress at A

4
Resultant load on Bolt B ,
tas
τA = RA = 19044 = 242.6 MPa
π (d) 2 π (10) 2
4
lda
RB = FP = 3333.33 N (FB = 0)
Maximum shear stress at B ,
τB = RB = 3333.33 = 42.5 MPa
π (d) 2 π (10) 2
4 4#
vi

SOL 5.22 Option (C) is correct.

Ci
w.
ww

Given : P = 400 N , r = 300 mm = 150 mm , l = 600 mm

2
x = 200 mm , μ = 0.25 and 2θ = 45c
Let, RN " Normal force pressing the brake block on the wheel
Ft "Tangential braking force or the frictional force acting at the
contact surface of the block & the wheel.

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CHAP 5 MACHINE DESIGN PAGE 235

Here the line of action of tangential braking force Ft passes through

the fulcrum O of the lever and brake wheel rotates clockwise. Then for
equilibrium, Taking the moment about the fulcrum O ,
RN # x = P # l
RN = P # l = 400 # 0.6 = 1200 N
x 0.2
Tangential braking force on the wheel,

m
Ft = μRN
Braking Torque, TB = Ft # r = μRN # r

.co
= 0.25 # 1200 # 0.15 = 45 N−m

SOL 5.23 Option (C) is correct.

Given : d = 20 mm , l = 700 mm ,

Compressive or working Load = 10 kN

tas
E = 200 GPa = 200 # 109 N/m2 = 200 # 103 N/mm2

According to Euler’s theory, the crippling or buckling load (Wcr ) under

various end conditions is given by the general equation,
lda
Wcr = cπ 2EI
2
...(i)
l
Given that one end is guided at the piston end and hinged at the other end.
So, c =2
vi

From equation (i),

Wcr = 2π 2EI = 2π2E # π d 4 I = π d4
2 2

l l 64 64
Ci

3
= 2 # 9.81 # 200 # 10 # 3.14 # (20) 4
(700) 2 64
= 62864.08 N = 62.864 kN
w.

We know that, factor of safety (FOS)

Crippling Load
FOS = = 62.864 = 6.28
Working Load 10
The most appropriate option is (C).
ww

SOL 5.24 Option (B) is correct.

Given : ZP = 20 , ZG = 40 , NP = 30 rev/ sec , P = 20 kW = 20 # 103 W ,
m = 5 mm
Module, m = D = DP = DG
Z ZP ZG
DP = m # ZP = 5 # 20 = 100 mm
or, DG = m # ZG = 5 # 40 = 200 mm
Centre distance for the gear set,
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PAGE 236 MACHINE DESIGN CHAP 5

L = DP + DG = 100 + 200 = 150 mm

2 2

SOL 5.25 Option (C) is correct.

Given :
Length of line of action, L = 19 mm
Pressure angle, φ = 20c

m
Length of path of contact (L)
Length of arc of contact =
cos φ
= 19 = 20.21 mm

.co
cos 20c
Contact ratio or number of pairs of teeth in contact,
Length of arc of contact
=
circular pitch

SOL 5.26 Option (C) is correct.

tas
= 20.21 = 20.21 = 1.29
πm 3.14 # 5
vi lda
Ci

Let, T " Torque transmitted in N − m

w.

We know that power transmitted is,

P = Tω = T # 2πN
60
3
T = 60P = 60 # 20 # 10 = 106.157 N−m
ww

2πN 2 # 3.14 # 1800

FT = T Tangential load on the pinion
RP
= 106.157 = 2123.14 N
0.05
From the geometry, total load due to power transmitted,
F = FT = 2123.14 - 2258.1 N
cos φ cos 20c

SOL 5.27 Option (A) is correct.

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CHAP 5 MACHINE DESIGN PAGE 237

Given : P = 5 kW , N = 2000 rpm , μ = 0.25 , r 2 = 25 mm = 0.025 m ,

p = 1 MPa
Power transmitted, P = 2πNT
60
3
Torque, T = 60P = 60 # 5 # 10 = 23.885 N−m
2πN 2 # 3.14 # 2000
When pressure is uniformly distributed over the entire area of the friction

m
faces, then total frictional torque acting on the friction surface or on the
clutch,
(r ) 3 − (r2) 3

.co
T = 2πμp ; 1 E
3
23.885 # 3 = 2 # 3.14 # 0.25 # 1 # 106 # [r 13 − (0.025) 3]
r 13 − (0.025) 3 = 23.885 # 3
2 # 3.14 # 0.25 # 106

tas
r 13 − 1.56 # 10−5 = 45.64 # 10−6 = 4.564 # 10−5
r 13 = (4.564 + 1.56) # 10−5 = 6.124 # 10−5
r1 = (6.124 # 10−5) 1/3 = 3.94 # 10−2 m = 39.4 mm
lda
SOL 5.28 Option (A) is correct.
Given : ZP = 19 , ZG = 37 , m = 5 mm
Also, m =D
Z
vi

For pinion, pitch circle diameter is,

DP = m # ZP = 5 # 19 = 95 mm
Ci

And pitch circle diameter of the gear,

DG = m # ZG = 5 # 37 = 185 mm
Now, centre distance between the gear pair (shafts),
L = DP + DG = 95 + 185 = 140 mm
w.

2 2 2

SOL 5.29 Option (C) is correct.

ww

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PAGE 238 MACHINE DESIGN CHAP 5

We know that in S-N curve the failure occurs at 106 cycles (at endurance
strength)
We have to make the S-N curve from the given data, on the scale of log 10 .
Now equation of line whose end point co-ordinates are
^log 10 1000, log 10 490h and ^log 10 10 , log 10 70h
6

or ^3, log 10 490h and ^6, log 10 70h,

m
y − log 10 490 log 10 70 − log 10 490 y − y1 y 2 − y1
x−3
=
6−3 b x − x1 = x 2 − x1 l
y − 2.69
= 1.845 − 2.69

.co
x−3 3
y − 2.69 =− 0.281 (x − 3) ...(i)
Given, the shaft is subject to an alternating stress of 100 MPa
So, y = log 10 100 = 2

tas
Substitute this value in equation (i), we get
2 − 2.69 =− 0.281 (x − 3)
− 0.69 =− 0.281x + 0.843
x = − 0.843 − 0.69 = 5.455
lda
− 0.281
And log 10 N = 5.455
N = 105.455 = 285101
The nearest shaft life is 281914 cycles.
vi

SOL 5.30 Option (B) is correct.

Ci
w.
ww

Given : l = 60 mm = 0.06 m , s = 6 mm = 0.006 m , P = 15 kN = 15 # 103 N

Shear strength = 200 MPa
We know that, if τ is the allowable shear stress for the weld metal, then the
shear strength of the joint for single parallel fillet weld,
P = Throat Area # Allowable shear stress
= t#l#τ

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CHAP 5 MACHINE DESIGN PAGE 239

P = 0.707s # l # τ t = s sin 45c = 0.707s

τ = P = 15 # 103 = 58.93 MPa
0.707 # s # l 0.707 # 0.006 # 0.06
Factor of Safety,
Shear strength
FOS = = 200 MPa = 3.39 - 3.4
Allowable shear stress 58.93 MPa

m
SOL 5.31 Option (A) is correct.
The coefficient of friction for a full lubricated journal bearing is a function
of three variables, i.e.

.co
μ = φ b ZN , d , l l
p c d
Here, ZN =Bearing characteristic Number, d =Diameter of the bearing
p
l =Length of the bearing, c =Diameteral clearance
Sommerfeld Number = ZN b d l
p c
tas
2

It is a dimensionless parameter used extensively in the design of journal

bearing. i.e. sommerfeld number is also function of b ZN , d l. Therefore
lda
p c
option (A) is correct.

SOL 5.32 Option (B) is correct.

vi
Ci
w.

Given : r = 200 mm = 0.2 m , θ = 270c = 270 # π = 3π radian , μ = 0.5

180 2
At the time of braking, maximum tension is generated at the fixed end of
ww

band near the wheel.

Let, T2 " Tension in the slack side of band
T1 "Tension in the tight side of band at the fixed end
Taking the moment about the point O ,
T2 # 1 = 100 # 2 & T2 = 200 N
For the band brake, the limiting ratio of the tension is given by the relation
T1 = eμθ & T1 = T2 # eμθ
T2

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PAGE 240 MACHINE DESIGN CHAP 5

3π
T1 = 200 # e0.5 # 2 = 200 # 10.54 = 2108 N
- 2110 N
So, maximum tension that can be generated in the band during braking is
equal to 2110 N

SOL 5.33 Option (B) is correct.

m
Maximum wheel torque or braking torque is given by,
TW = (T1 − T2) r = (2110 − 200) # 0.2 = 382 N−m

.co
SOL 5.34 Option (D) is correct.

tas
Given : ZP = 40 teeth , ZG = 120 teeth , NP = 1200 rpm , TP = 20 N−m
lda
Velocity Ratio, ZP = NG
ZG NP
NG = ZP # NP = 40 # 1200 = 400 rpm
ZG 120
vi

Power transmitted is same for both pinion & Gear.

P = 2πNP TP = 2πNG TG
60 60
Ci

NP TP = NG TG

TG = NP TP = 1200 # 20 = 60 N−m
NG 400
w.

So, the torque transmitted by the Gear is 60 N−m

SOL 5.35 Option (A) is correct.

ww

When the notch sensitivity factor q is used in cyclic loading, then fatigue
stress concentration factor may be obtained from the following relation.
K f = 1 + q (Kt − 1)
K f − 1 = q (Kt − 1)
K −1
q = f
Kt − 1

SOL 5.36 Option (C) is correct.

The S-N curve for the steel is shown below :

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CHAP 5 MACHINE DESIGN PAGE 241

m
.co
We can easily see from the S-N curve that, steel becomes asymptotic nearly
at 106 cycles .

SOL 5.37 Option (C) is correct. tas

Given : Ft = 2200 N , p = 4 mm = 0.004 m
lda
Torque required for achieving the tightening force is,
T = Ft # r = Ft # Pitch = 2200 # 0.004 = 1.4 N−m
2π 2 # 3.14

SOL 5.38 Option (B) is correct.

vi

Type of Gears Arrangement of shafts

P. Bevel gears 2. Non-parallel intersecting shafts
Ci

Q. Worm gears 3. Non-parallel, non-intersecting shafts

R. Herringbone gears 4. Parallel shafts
S. Hypoid gears 1. Non-parallel off-set shafts
w.

So, correct pairs are P-2, Q-3, R-4, S-1.

SOL 5.39 Option (C) is correct.

ww

The wire ropes are designated by the number of strands multiplied by the
number of wires in each strand. Therefore,
6 # 19 = Number of strands # Number of wires in each strand.

SOL 5.40 Option (C) is correct.

Given : Diameter of shaft = d
Torque transmitted = T
Length of the key = l
We know that, width and thickness of a square key are equal.
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PAGE 242 MACHINE DESIGN CHAP 5

i.e. w =t=d
4
Force acting on circumference of shaft
F = T = 2T (r = d/2)
r d
Shearing Area, A = width # length = d # l = dl
4 4

m
2T/d
Average shear stress, τ = Force = = 8T2
shearing Area dl/4 ld

.co
SOL 5.41 Option (D) is correct.
Let, T1 " Tension in the tight side of the band,
T2 " Tension in the slack side of the band
θ "Angle of lap of the band on the drum

T2 180
tas
Given : T1 = 3 , θ = 180c = π # 180 = π radian
For band brake, the limiting ratio of the tension is given by the relation,

bT2 l
T1 = eμθ or 2.3 log T1 = μθ
T2
lda
2.3 # log (3) = μ # π
2.3 # 0.4771 = μ # 3.14

μ = 1.09733 = 0.349 - 0.35

3.14
vi

SOL 5.42 Option (A) is correct.

Ci
w.
ww

Let N1 , N2 , N 3 and N 4 are the speeds of pinion 1, gear 2, pinion 3 and gear
4 respectively.
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CHAP 5 MACHINE DESIGN PAGE 243

Given : Z1 = 16 teeth , Z 3 = 15 teeth and Z 4 = ? , Z2 = ?

Velocity ratio N1 = Z2 /Z1 N \ 1/Z
N4 Z 3 /Z 4
= Z2 # Z 4 = 12 ...(i)
Z1 Z3
But for stage 1, N1 = Z 2 = 4 ...(ii)
N2 Z1

m
So, 4 # Z 4 = 12 from eq. (i)
Z3
Z4 = 3, & Z 4 = 3 # 15 = 45 teeth

.co
Z3
From equation (ii), Z2 = 4 # Z1 = 4 # 16 = 64 teeth

SOL 5.43 Option (B) is correct.

But, D4 = D3 = 4
tas
Let centre distance in the second stage is D .
D = R4 + R3 = D4 + D3
2
m = D/Z module
lda
Z4 Z3
D 4 = 4 # Z 4 = 4 # 45 = 180
Or, D 3 = 4 # Z 3 = 4 # 15 = 60

So, D = 180 + 60 = 120 mm

vi

SOL 5.44 Option (C) is correct.

Ci

In standard full height involute teeth gear mechanism the arc of approach is
not be less than the circular pitch, therefore
Maximum length of arc of approach = Circular pitch
...(i)
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where Maximum length of the arc of approach

Max. length of the path of approach
=
cos φ
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r sin φ
= = r tan φ
cos φ
Circular pitch, PC = πm = 2πr m = 2r
Z Z
Hence, from equation (i), we get
r tan φ = 2πr
Z
Z = 2π = 2π = 17.25 - 18 teeth
tan φ tan 20c

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PAGE 244 MACHINE DESIGN CHAP 5

SOL 5.45 Option (D) is correct.

(A) Flange coupling :- It is used to connect two shaft having perfect coaxial
alignment and no misalignment is allowed between them.
(B) Oldham’s coupling :- It is used to join two shafts which have lateral mis-
alignment.
(C) Flexible bush coupling :- It is used to join the abutting ends of shafts

m
when they are not in exact alignment.
(D) Hook’s joint :- It is used to connect two shafts with large angular
misalignment.

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SOL 5.46 Option (D) is correct.
When the shaft rotates, the bending stress at the upper fibre varies from
maximum compressive to maximum tensile while the bending stress at the

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lower fibres varies from maximum tensile to maximum compressive. The
specimen subjected to a completely reversed stress cycle. This is shown in
the figure.
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When shaft is subjected to repeated stress, then it will be designed for

fatigue loading.
w.

SOL 5.47 Option (B) is correct.

For a worm gear the velocity ratio ranges between 10 : 1 to 100 : 1. So, Large
speed reductions (greater than 20) in one stage of a gear train are possible
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through worm gearing.

SOL 5.48 Option (A) is correct.

For Helical spring, deflection is given by,
3 3
δ = 64PR4 n = 8PD4 n
Gd Gd
where, P = Compressive load
d = Wire diameter
R = Coil diameter
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CHAP 5 MACHINE DESIGN PAGE 245

G = Modulus of rigidity
From the given conditions
δ \ 14
d
Given d1 = 1 cm and d2 = 2 cm

δ2 = d1 4
δ1 b d2 l

m
δ2 = 1 4 = 1
δ1 b 2 l 16

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δ2 = δ1
16
So, deflection will decrease by a factor of 16.

Option (C) is correct.

SOL 5.49

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Bars AB and BC have negligible mass. The support load P acting at the
free end of bars AB and BC . Due to this load P , In bar AB compressive
stress and in bar BC tensile stress are induced.
However, none of these bars will be subjected to bending because there is no
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couple acting on the bars.

SOL 5.50 Option (C) is correct.

Let L1 & L2 are lengths of the springs and n1 & n2 are the number of coils
vi

in both the springs.

Given : W1 = W2
= m2 g
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m1 g
ρν1 g = ρν2 g m = ρν
A 1 # L 1 # ρg = A 2 # L 2 # ρg
π d 2 πD n = π d 22 # πD2 n2
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L = πDn
4 1# 1 1
4
d 12 # n1 = d 22 # n2 D1 = D 2
Given : d1 = d & d 2 = d
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2
2
d 2 # n1 = d # n 2
4
or, n1 = n 2
4
The deflection of helical spring is given by,
3
δ = 8PD4 n
Gd
4
Spring stiffness, k = P = Gd3
δ 8D n
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PAGE 246 MACHINE DESIGN CHAP 5

From the given conditions, we get

4
k\d
n

k 2 b d 2 l # a n1 k
So, k 1 = d1 4 n2

k2 c d/2 m # n2 /4
k1 = d 4 n2

m
k1 = 16 4 = 64
k2 #

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*******

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