Government Engineering College, Bhavnagar

Mechanical Engineering Department

Fundamental of Machine Design

(3141907)

Semester – 4
EVEN 2022-23
 Fundamental of Machine Design (3141907)

Index
Sr.
Title CO Date Marks Sign
No.
Exercise on material selection
1 1
for given application

Detail and assembly of

2 1
mechanism/ machine.

Problems related to
3 fundamentals of design (chapter 2
no. 1 to 4).

Design and drawing of Joints

4 4
and levers.

Design and drawing of screw

5 4
jacks (Bottle neck and Toggle).

6 Design of beam and columns 3

7 Design of shaft and keys 4

Design of machine components

8 5
under fluctuates loading.

Case study for design of

9 5
mechanical components.

2D drawing of machine
10 components using computer 4
software.

Total

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Practical 1
Exercise on material selection for given application

1. Introduction
1.1 Material importance in design
1.2 Availability of different material
1.3 Importance of composition of different material which lead to properties
variation, affects the functionality of machine element
1.4 Importance of heat treatment to develop specific properties. Explain with
example

2. Select any component of automobile.

2.1 Define the working condition (design point of view) & work environment in
which component will function
2.2 Enlist the properties requirement based on above point with proper reason
2.3 Enlist the suitable materials which full-fill major requirement using IS code.
2.4 List out the properties which need to develop.
2.5 Check out whether process affects the major requirement.
2.6 Comparison of cost of material & process.
2.7 Final Selection of material.

3. Select any machine element.

3.1 Repeat the same process as of point 2.

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Practical 2
Detail and assembly of mechanism/machine.

1. Prepare the detail drawing for given assembly

2. Prepare the assembly drawing for given parts

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 Fundamental of Machine Design (3141907)

Practical 3

Problems related to fundamentals of design

(Chapter no. 1 to 4)

1. A reciprocating steam engine connecting rod is subjected to a maximum load of 65

kN Find the diameter of the connecting rod at its thinnest part, if the permissible

tensile stress is 35 N/mm2.

2. A composite bar made up of aluminum bar and steel bar, is firmly held between two
unyielding supports as shown in figure.

3. A bar of 2 m length, 20 mm breadth and 15 mm thickness is subjected to a tensile

load of 30 kN Find the final volume of the bar, if the Poisson’s ratio is 0.25 and

Young's modulus is 200 GN/m2.

4. Find the moment of inertia of a T-section with flange as 150 mm × 50 mm and web as
150 mm × 50 mm about X-X and Y-Y axes through the center of gravity of the section.

5. An I-section is made up of three rectangles as shown in Figure. Find the moment of

inertia of the section about the horizontal axis passing through the Centre of gravity
of the section.

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 Fundamental of Machine Design (3141907)
6. A rectangular hole is made in a triangular section as shown in figure. Determine the
moment of inertia of the section about X-X axis passing through its center of gravity
and the base BC.
7. A cast iron water pipe 50 cm bore and 2 cm thick is supported over a span of 10
meters. Find the maximum stress in the metal when the pipe is running full. Density

of cast iron is 7300kg/m3.

8. Discuss in brief about torsional rigidity.
9. A hollow circular shaft is required to transmit 300 metric horsepower at 200 r.p.m.
The maximum torque developed is 1·5 times the mean torque. Determine the
external diameter of the shaft if it is double the internal diameter if the maximum

shear stress is not to exceed 800 kg/cm2.

10. A solid circular steel shaft is transmitting 150 kW at 300 rpm. Determine the

diameter of the shaft if the maximum shear stress is not to exceed 80 N/mm2 and

angular twist per meter length of the shaft is not to exceed 1 °. Take G = 80 kN/mm2.
11. Explain Stress – Strain Relationship for Mild Steel.
12. Define following Terms.
a. Stress (Tensile, Compressive, Shear)
b. Strain (Longitudinal, Lateral, Volumetric, Shear)
c. Bending Stress.
d. Torsional Stress.
e. Bearing or Crushing Stress.
f. Modulus of Elasticity.
g. Modulus of Rigidity.
h. Poisson’s Ratio.
i. Bulk Modulus.
j. Centroid
k. Centre of Gravity.
l. Centre of Mass.
m. Moment of Inertia
n. Radius of Gyration.
o. Section Modulus.

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 Fundamental of Machine Design (3141907)

Practical 4
Design and drawing of Joints and levers.
1. What is meant by eccentric loading and eccentricity?
2. Distinguish between cotter joint and knuckle joint.
3. Define cotter. Why taper is provided on a cotter?
4. Two rods of 50 mm diameter are to be joined by the cotter joint with a cotter
thickness of 12.5 mm. If the joint is required to withstand a pull of (50+a) kN (Note:
a = Last two digit of your enrolment number) Ultimate tensile strength of material
is 300 MPa and factor of safety is 5. Design Cotter, socket and spigot.
5. Design a knuckle joint for a tie rod of a circular section to sustain a maximum pull
of (70+a) kN the ultimate tensile strength of the material used for rod is 420
N/mm2. The ultimate tensile and shearing strength of the pin material are 510
N/mm2 and 396 N/mm2 respectively. Take factor of safety as 6 (Note: a = Last two
digit of your enrolment number).
a) Design Single Eye / Rod end
b) Design Double Eye / Forked end.
c) Design Knuckle Pin.
6. What is lever? Gives its applications and explain different classes of lever.
7. A right-angled bell- crank lever is to be designed to raise a load of 5kN at the short
arm end. The length of short & long arms is 100 & 450 mm respectively. The lever
& pins are made of steel 30C8 (Syt=400N/mm2) & the factor of safety is 5. The
permissible bearing pressure on pin is 10N/mm2. The lever has a rectangular
cross-section & the ratio of width to thickness is 3:1. The length to diameter ratio
of fulcrum pin is 1.25:1. Assume that the arm of the bending moment on the lever
extends up to the axis of the fulcrum. Calculate
a) The diameter & length of the fulcrum pin.
b) The shear stress in pin
c) The dimensions of the boss of the lever at the fulcrum.
d) d. The dimensions of cross-section of the lever

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 Fundamental of Machine Design (3141907)
8. A vertical lever PQR, 15mm thickness is attached by a fulcrum pin at R and a
horizontal rod at Q, as shown in Fig.7. An operating force of 900N is applied
horizontally at P. Calculate
a) Reaction at Q & R.
b) Tensile stress in 12mm diameter tie rod at Q.
c) Shear stress in 12mm diameter pins at P, Q & R. d.
d) Bearing stress on the lever at Q.

9. Prepare a drawing sheet for problem no. 4

10. Prepare a drawing sheet for problem no. 5

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Practical 5
Design and drawing of screw jacks
(Bottle neck and Toggle)

1. A screw jack is required to lift a load of 80 KN through a height of 400 mm. The
elastic strength of screw material in tension and compression is 200 MPa and in
shear 120 MPa. The material for nut is phosphor-bronze for which the elastic limit
may be taken as 100 MPa in tension, 90 MPa in compression and 80 MPa in shear.
The bearing pressure between the nut and the screw is not to exceed 18 N/mm2.
Design and draw the screw jack.

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 Fundamental of Machine Design (3141907)
2. A toggle jack as shown in figure, is to be designed for lifting a load of 4 kN When
the jack is in the top position, the distance between the center lines of nuts is 50
mm and in the bottom position this distance is 210 mm. The eight links of the jack
are symmetrical and 110 mm long. The link pins in the base are set 30 mm apart.
The links, screw and pins are made from mild steel for which the permissible
stresses are 100 MPa in tension and 50 MPa in shear. The bearing pressure on the
pins is limited to 20 N/mm2. Assume the pitch of the square threads as 6 mm and
the coefficient of friction between threads as 0.20.

3. Explain the different types of threads used in power screw stating their
applications.
4. What do you understand by self-locking screw? Explain the condition for self-
locking.
5. What is self-locking and overhauling power screw? What is significance of these
properties?
6. How will you select the material for screw and nut while designing power screw?
7. What is self-locking of power screw? Explain.
8. What do you understand by overhauling of screw?

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Practical 6

Design of beam and columns

1. What do you understand by a column or strut? Explain various end condition of
a column or strut.
2. State the assumption used in Euler’s column theory.
3. Define ‘slenderness ratio’. How it is used to define long and short column?
4. How the piston rod is designed?
5. Explain the design procedure of valve push rod.
6. A T-section 150 mm × 120 mm × 20 mm is used as a strut of 4 m long hinged at
both ends. Calculate the crippling load, if young’s modulus for the material of the
section is200 kN/mm2.
7. Calculate the diameter of a piston rod for a cylinder of 1.5 m diameter in which
the greatest difference of steam pressure on the two sides of the piston may be
assumed to be 0.2 N/mm2. The rod is made of mild steel and is secured to the
piston by a tapered rod and nut and to the crosshead by a cotter. Assume modulus
of elasticity as 200 kN/mm2 and factor of safety as 8. The length of rod may be
assumed as 3 meters.
8. Determine the dimensions of an I-section connecting rod for a petrol engine from
the following data: Diameter of the piston = 110 mm, Mass of the reciprocating
parts = 2 kg, Length of the connecting rod from center to center = 325 mm, Stroke
length = 150 mm, R.P.M. = 1500 with possible over speed of 2500, Compression
ratio = 4: 1, Maximum explosion pressure = 2.5 N/mm2.
9. Draw shear force and bending moment diagram for the cantilever beam shown
in figure.

10. Draw the SF and BM diagrams for the beam shown in Figure and find out the
position and the magnitude of maximum moment.

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 Fundamental of Machine Design (3141907)

11. The overhanging beam ABC is supported at A and B, the span AB being 6 m. The
overhang BC is 2 m. It carries a uniformly distributed load of 30 kN/m over a
length of 3 m from A and concentrated load of 20 kN at free end. Draw SF and BM
diagrams.

12. Draw BM and SF diagrams for the beam shown in Figure, indicating the values at
all salient points.

13. Determine the reactions and construct the shear force and bending moment
diagrams for the beam shown in Figure. Mark the salient points and the values at
those points.

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 Fundamental of Machine Design (3141907)

Practical 7
Design of Shafts and Keys.
1. What is ASME code for shaft design.
2. Compare the weight, strength and rigidity of a hollow shaft of same external diameter
as that of solid shafts, both the shafts are made of same material. Assume that
diameter ratio for the hollow shaft is di/do = 0.6
3. State & explain the various criteria on which shaft are designed?
4. State and explain the failures of shafts stating the reasons.
5. Explain the design of shaft based on strength and rigidity as per A.S.M.E. code.
6. Explain different types of keys with its applications.
7. “Square key is stronger against crushing than rectangular key”. Justify the statement.
Explain purpose and requirement of shaft coupling compare the strengths of square
key and rectangular key.
8. Find the diameter of a solid steel shaft to transmit 20 kW at 200 r.p.m. The ultimate
shear stress for the steel may be taken as 360 MPa and a factor of safety as 8. If a
hollow shaft is to be used in place of the solid shaft, find the inside and outside
diameter when the ratio of inside to outside diameters is 0.5.
9. A shaft supported at the ends in ball bearings carries a straight tooth spur gear at its
mid span and is to transmit 7.5 kW at 300 r.p.m. The pitch circle diameter of the gear
is 150 mm. The distances between the center line of bearings and gear are 100 mm
each. If the shaft is made of steel and the allowable shear stress is 45 MPa, determine
the diameter of the shaft. Show in a sketch how the gear will be mounted on the shaft;
also indicate the ends where the bearings will be mounted? The pressure angle of the
gear may be taken as 20°.
10. A shaft is supported by two bearings placed 1 m apart. A 600 mm diameter pulley is
mounted at a distance of 300 mm to the right of left hand bearing and this drives a
pulley directly below it with the help of belt having maximum tension of 2.25 kN
Another pulley 400 mm diameter is placed 200 mm to the left of right hand bearing
and is driven with the help of electric motor and belt, which is placed horizontally to
the right. The angle of contact for both the pulleys is 180° and μ = 0.24. Determine the
suitable diameter for a solid shaft, allowing working stress of 63 MPa in tension and
42 MPa in shear for the material of shaft. Assume that the torque on one pulley is
equal to that on the other pulley.

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Practical 8
Design of machine components under fluctuates loading.

1. A machine component is subjected to a flexural stress which fluctuates between +

300 MPa and – 150 MPa. Determine the value of minimum ultimate strength
according to 1. Gerber relation; 2. Modified Goodman relation; and 3. Soderberg
relation. Take yield strength = 0.55 Ultimate strength; Endurance strength = 0.5
Ultimate strength; and factor of safety = 2.

2. A bar of circular cross-section is subjected to alternating tensile forces varying from

a minimum of 200 kN to a maximum of 500 kN It is to be manufactured of a material
with an ultimate tensile strength of 900 MPa and an endurance limit of 700 MPa.
Determine the diameter of bar using safety factors of 3.5 related to ultimate tensile
strength and 4 related to endurance limit and a stress concentration factor of 1.65
for fatigue load. Use Goodman straight line as basis for design.

3. A hot rolled steel shaft is subjected to a torsional moment that varies from 330 N-m
clockwise to 110 N-m counter clockwise and an applied bending moment at a
critical section varies from 440 N-m to – 220 N-m. The shaft is of uniform cross-
section and no keyway is present at the critical section. Determine the required
shaft diameter. The material has an ultimate strength of 550 MPa and a yield
strength of 410 MPa. Take the endurance limit as half the ultimate strength, factor
of safety of 2, size factor of 0.85 and a surface finish factor of 0.62.

4. A steel cantilever beam, as shown in Fig., is subjected to a transverse load at its end
that varies from 45 N up to 135 N down as the axial load varies from 110 N
(compression) to 450 N (tension). Determine the required diameter at the change
of section for infinite life using a factor of safety of 2. The strength properties are as
follows: Ultimate strength = 550 MPa, Yield strength = 470 MPa, Endurance limit =
275 MPa

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Practical 9

Find a case study which is related to machine component design and prepare a report
which included problems faced, solutions offered and their effect on outcome.

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Practical 10
2D drawing of machine components using computer software.

1. Using data of problem 4 of practical 4, develop the detail and assembly

drawing of cotter joint.

2. Using data of problem 5 of practical 4, develop the detail and assembly

drawing of knuckle joint.

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