AMIE Study Material & Admission Packages AMIE(I) Study Circle, Roorkee www.amiestudycircle.

com

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$'16:7 AN:MC407/PR407 (1500)

DESIGN OF MACHINE ELEMENTS

1ime : Three hours
Maximum Marks: JOO
Answer FIVE questions, taking ANY TWO from Group A,
ANY TWO from Group B and ALL from Group C.

All parts of a question ( a,b,etc.) should

he answered at one place.
Answer should be brief and to-the-point and be supplemented
with neat sketches. Unnecessary long answers may
result in loss of marks.
Any missing or wrong data may he assumed suitably gMng
proper justification. · ··
Figures on the right-hand side margin indicate fall marks. ·

Group A
J• (a) Define resilience and discuss its implication in the choice
of material in machine design. 6
(h) What are the various means by which a surface
texture is specified ? 6

(c) A short hollow cylindrical column (Fig. I) of 200 mm

inner diameter and 300 mm outer diameter carries a
vertical eccenlric load ofSOO kN in oneofthediamelral
planes, the eccentricity being 100 mm. Determine the
maximum intensity of the stress induced and state its
nature. What is the maximum permissible eccentricity
of the above load, if the stress induced throughout the
cross-section is to be compressive in nature ? 8

37
AMIE Study Material & Admission Packages AMIE(I) Study Circle, Roorkee www.amiestudycircle.com

(c) A300mmextra-heavylapjoint stub end nozzle is

attached by welding to a vessel that has an inside
diameter of 1.5 m and a shell thickness of20 mm. The
material of the shell and reinforcement plate confonns
to grade 2B of IS 2002-1962. The vessel operates at
1·72 MPa and 370°C. There is no allowance for
corrosion and the vessel is not stress relieved. Check
the adequacy of the reinforcement plate as shown in
Fig. 2. Allowable stress for grade 2B steel up to 375°C
is9H6MN/m2• 10

Fig. I
Z. (a) What are different types offrts as per IS? Give an
example of each type and state the application of each
type. 6

(b) What are the general assumptions that are normally

made while using Hertz contact stress fonnulae ? 6
Fig.2
(c) A~ of circular cross-section is subjected to an
alternating tensile force varying :from 20 kN to 70 kN. 4. (a) Explain various tightening stresses set-up in a bolt and
Determine the diameter of the rod according to the effect of a gasket in a bolted joint. 6
( i) Gerber method, ( ii) Goodman method, and
( b) What is a key and the purpose for which it is used ?
( iii) Soderberg method using following material
Neatly draw a Woodruff key and show its uses? 6
property: lITS = 1000 MPaandyield strength= 550MPa.
Take a factor of safety 2, neglecting stress (c) Determine the sm: of the welds for the eccentrically
concentration effect and other correction factor. 8 loaded member shown in Fig. 3. Permissible normal
stress for the weld material is 75 MPa. 8
3. (a) What do you mean by surface finish factor as applied F= lOkN -
to variable loading problem? What is the significance - -- - I I

T
and application ofthis factor? 5 I b=10
I
I
(b) What is autofrettage ? What are its advantages over
other methods of strengthening a thick cylinder? 5 L=250--=,j L-so,
Fig.3
S'16: 7 AN: MC407/PR407 (1SOO) ( 2 ) ( Continued)
S'l6:7AN:MC407/PR407 (!:SOO) ( 3) ( Tum Ow,,.)

38
AMIE Study Material & Admission Packages AMIE(I) Study Circle, Roorkee www.amiestudycircle.com

having an ultimate strength of 140 MPa in tension and

Groap B 560 MPa in compression. The diameter of the crack
5. (a) What is Belleville spring? In what forms these springs pin is 120 mm and its length is also same as crack pin.
can be used ? S Assuming a fackir of safety of 4 for the cap material
and permissible stress for the bolt material as 70 MPa,
(b) Wbatdo you understand by the tenn 'nipping' ofspring determine the thickness of the cap and siz.e ofthe bolts. 8
leaves? Find and show the deflection of the extra full
length leaves from the graduated leaves. S (c) Differentiate between rated and average life of
anti-friction bearing. Also, explain about the selectioo
(c) Figure 4 shows a steel cantrilever beam of uniform procedure of anti-friction bearing. 6
strength (in the form of triangular plate), with a helical
compression spring placed below it at its free end. 7. (a) What is the significance of determining the beam
The width of the beam at its fixed end is SOO mm and strength of a gear ? S
its thickness is 12 mm. The compression spring has 10 (b) Operation ofhelical gearing, compared to spur gearing,
active coils of l O mm wire diameter and 80 mm is relatively silent. Justify the statement. S
mean coil diameter. Take G = 0-84 x lo' MPa and
E= 2·1 x 105 MPa. 10 (c) Why is heat ~ce an important aspect in the design
of gears? S
lf.--700mm
(d) Why is gear lubrication necessary? Explain the
requirements of a gear lubricant S

8. (a) Explain the step-by-step procedure of designing steel

Fig.4 wire ropes. 8

(i) What force, F, if gradually applied at the end of ( b) A simple chain no. OSB is used to transmit power from
the beam. will cause a deflection of 35 mm ? a 1400 rpm electric motor to a line shaft running at
350 rpm. The operation is smooth without any shock.
(ii) What is the bending stress induced in the beam at Detennine the following: 6+ 6 .
a section 350 mm from the fixed end?
(,) Rated power based on breaking load for which
(iii) How much energy is absorbed by the coil spring? the drive can be recommended.

6. (a) Show the pressure distribution in a journal bearing with (ii) Tension in the chain for the above rated power.
thick film lubrication in axial and radial direction. 6 The following data DUI.Y be taken :
(J) No. of sprocket pinion teeth for the velocity
(b) The connecting rod cap ofan engine is required to resist
ratio 4 as 23. ·
a maximum load of25 kN. TI1e ~p is made of cast-iron
S'16:7AN:MC407/PR407 (1500) ( S)
S'l6:7AN:MC407lPR40i (ISi)O) ( 4) ( Conlinued)

39
AMIE Study Material & Admission Packages AMIE(I) Study Circle, Roorkee www.amiestudycircle.com

(II) Braking load for chain 08 B I$ i 7.f{ kN and

pitch of the chain link l;IS 12·70 mm.

Group C

9. Explain the following in brief: 5x4

(1) Preferred number and its importance in machine
design.
(ii) Self-actuating and self-energizing brake.
(iii) Explain why, under static loading, stress concentration
factor is ignored for ductile material.
(iv) Lewis equation for bevel gears.

( v) Universal flexible coupling.

S'l6:7 AN:MC407/PR407 (1500) ( 6 )

40
AMIE Study Material & Admission Packages AMIE(I) Study Circle, Roorkee www.amiestudycircle.com

W'l6: 7 AN: MC 407/PR407 (1500)

DESIGN OF MACHINE ELEMENTS

Time : Three hours
Maximum Marks : JOO
Answer FIVE questions. taking ANY TWO from Group A,
ANY TWO from Group B and ALL from Group C.
All parts of a question ( a, b, etc.) should
be answered at one place.
Answer should be brief and to-the-point and be supplemented
with neat sketches. Unnecessary long answers may
result in loss of marks.
Any missing or wrong data may be assumed suitably giving
proper justification.
Figures on the right-hand side margin indicate full marks.

Group A
1. (a) Describe the rules to be followed in carrying out the
engineering design process. 8
( b) Enumerate the standards used in mechanical
engineering design in a broader perspective. 6
(c) Explain the aspects of choosing correct carbon
content in carbon steels for a particular application. 6

2. (a) Brief on the effecty ofloading uncertainty and type of

loading in assigning a suitable factor of safety in
design. 5
( b) Illustrate the buckling of connecting rod. Prove that
I-section is ideally suitable for connecting rod based
on buckling consideration. 5

( Turn Over)

41
AMIE Study Material & Admission Packages AMIE(I) Study Circle, Roorkee www.amiestudycircle.com

(c) Fig.1 show a hanger with rectangular cross-s~ction,

with the proportions indicated. The force, F actmg on ( h) How does stress concentration occur in butt and fillet
the hanger is 5 kN as shown in figure. The permis,ible welds ? Give two examples that illustrate the reduction
stress in the hanger material is 50 MPa. Detem1i11e the of stress concentration. 6
size of the cross-section. Take b = 2t. I{)
(c) A machine vice has single start square threads with
20 mm nominal diameter and 4 mm pitch. The inner
and outer diameters of the friction collar are 12 mm
and 25 mm respectively. The coefficient of friction for
threads and collar are 0.15 and 0.20 respectively. If
the person operating the vice can exert a force of
I 00 Non the handle, at a radius of 180 mm, determine
(i) the clamping force developed between the jaws,
and
f-125---+-j
(ii) the efficiency of the clamp
Fig. 1
Assume uniform pressure at the contacting collar
J. (a) State the maximum shear stress theory and deduce the surface. 10
criterion of failure for the same. 5
Group B
( b) Brief on the factors affecting endurance limit. 5
(a) Mention the advantages and disadvantage of using
( c) A pusher rod for the fuel pump of an automobile is to~ rectangular wire as compared to round wire, in
designed for a repeated axial load of 8 kN. The material compression helical springs. 4
of the rod has yield strength of 380 MPa and an
endurance limit of 175 MPa for repeated axial loading. ( b) Explain the types of friction in sliding contract bearings. 6
The fatigue strength of the material for repeated axial (c) A rail wagon of240 kN is moving with a velocity of
loading is 252 MPa at 1,00,000 cycles. Determine the
2 m/s . It has to be broughttorestbytwo buffer springs.
required diameter of the pusher rod for a finite life of
Mean diameter of the springs is 330 mm and the
l 00 OOO cycles and for an infinite life. Consider a permissible stress is 660 N/mm 2• Design the springs
f~tig~e stress concentration factor of I, size factor of taking the maximum deflection as 140 mm. 10
0-85 and surface finish factor of 0.9. Take a factor of
safety of 2. 10 6. (a) Brief on the surface failures that occur in gears with
suitable illustrations. 4
4. (a) Mention the aspects by which a hexagonal head differs
from square in bolted joints. 4 ( h) Obtain an expression for form factor and brief on the
significance of the same in spur gear design. 6
W'16:7 AN :MC 407/PR407 (1500) ( 2 ) ( Contimu·d)
W' 16: 7 AN: MC 407/PR407 {1500) ( 3 ) ( Turn Over)

42
AMIE Study Material & Admission Packages AMIE(I) Study Circle, Roorkee www.amiestudycircle.com

intensity of pressure between the contact surfaces is

(c) A ball bearing is required to resist a radial load of 0·08 N/mm 2 • The coefficient of friction is 0·25. Eight
l O kN and a thrust load of 5 kN. The average life of helical compression springs are used to provide the axial
the bearing is to be 5000 hours, with inner race rotation force necessary to engage the cluth. If the stiffness of
at 950 r.p.m. What basic dynamic load rating must be each spring is 30 N/mm, determine the size of the
used in selecting the bearing? If this bearing is to have friction lining and the intial compression in the springs. g
a life ofSOOO hours at a reliability of95%, what is the
required basic dynamic load rating? lO Group C

7. (a) Illustrate the failure modes of keys and give the 9. Explain the following in brief: 10 X 2
necessruy equations. 4 (0 Fourth typical applications ofalloy steel

(b) How is a rubber bush designed in a bushed-pin type (i1) Stress due to eccentric loading
flexible coupling? Obtain the equations for determining (iii) Types of variable load with examples
the dimensions of the bush. 6
(iv) Methods for preventing thread loosening in bolted
(c) The shaft used in an axial flow rotary compressor is joints
subjected to a maximum torque of 1500 Nm and a (v) Types of rivets
3.
maximum bending moment of3000 Nm. Neglecting
the axial load on the compressor shall,, determine the (v1) Non-ferrous materials for springs
diameter of the shaft. Assume that the load is applied (vii) Comparison of full depth and stub teeth in gears
gradually. The shear stress in the shaft is limited to
(vii,) Spigot and socket joint for pipes
50 N/mm2 • Also design a hollow shaft for the above
compressor taking inner diameter as 0.4 times the outer (ix) Wet and dry operation of clutches
diameter. What is the percentage of material saving in (x) Failure in chain drives.
hollow shaft? Take fatigue factors kb= 1·5, k, = 1. 10

8. (a) Briefon the types of failure in roller chains. 4

( b) Obtain an expression for actuating force on the lever

for a block brake with short shoe. Brief on the three
different case possible depending on the magnitude of
coefficient of friction and location of hinge pin. -:

(c) A single disc cluth is required to resist a maximwn torque

of 450 N-m. The outer radius of the friction lining is
25% more than the inner radius. The permissible
W'l6:7AN:MC407/PR407 (1500) ( 5) AG-2,750
W'16:7AN:MC407/PR407(1500) ( 4) ( Continued)

43
AMIE Study Material & Admission Packages AMIE(I) Study Circle, Roorkee www.amiestudycircle.com

S'17:7 AN:MC407/PR407 (1500)

DESIGN OF MACHINE ELEMENTS

Time : .Three hours
Maximum Marks: 100
Ans1t•er FIVE questions, taking ANY rwo from Group A,
ANYTWO/rom Groap 8 and.ALLfrom Group C.

All parts of a question ( a,b,e1c.) should

be answered aJ one place.
Answer should be brief and to-the-point and be supplemented
with neat sketches. Unnecessary long answers may
re.vult in lo.u of marks.
A1~y mi~sing or wrong datll may be tissumed suitably giving
proper justification.
Figures on the right-hand side margin indicate full marks.

Group A
I. (a) What lilJ'C the basic requirements of mach.iru:
elements? Explain briefly. 5
(b) Discuss the importance of codes for design and
design data handbook. What are the standards used in
mechanical engineering design ? 5
(c) A cast iron pulley transmits 10 kW at400r.p.m. The
diamcterofthepulley is l-2meterandithasfOW'straight -
arms ofelliptical cross-section, in which the major axis
is twice the minor axis. Determine the dimensions of
the ann if the aUowable bending stress is 15 MPa. 10

2. (a,1 Draw the stress strain curve for ductile materials and
eirplain lhe saiient point1:, ,)n 1L 5

44
AMIE Study Material & Admission Packages AMIE(I) Study Circle, Roorkee www.amiestudycircle.com

( b) Define the following mechanical properties and their (c) What is eccentric riveted joint? Explain the method
importance in mechanical engineering design : S adopted for designing such joint. 6
(1) Malleabilily
(d) Discuss the eflect of surface treatments on fatigue life
(i1) Creep of components. 4
(ii,)Elasticity
(iv) Stiffiless Group B
(v) Resilience. 5. (a) What is the Wahl factor? Why is it used? 2
(c) A cylindrical shaft made of steel of yield strength (b) A railway wagon moving at a velocity of l ·5 m/s is
700 MPa is subjected to static loads consisting of brought to rest by a bumper consisting of two helical
bending moment 10 kN-m and a torsional moment of
springs arranged in parallel. The ma.-.s of the wagon is
30 kN-m. Determine the diameter of the shaft using
1500 kg. The springs are compressed by l 5U mm in
(i) maximum shear stress theory (ii) maxirnwn strain
bringing the wagan to rest. The spring index can he
energy theory. Take E = 210 GPa and poissons ration
is0-25. 10
a-.
taken 6. The springs having ultimate tensile strength
of 1250 N/mm2 and modulus of rigidity of
3. (a) What do you understand by stress concentration? 81370 N/mm2• The permissible shear stress for the
Discuss the causes of stress concentration. 4 spring wire can be taken as 50% of the ultimate
tensile strengt.h. Design the spring and calculate :
(b) What are the advantages of square threads over (i) wire diameter; (ii) mean coil diameter; (iii) number
trapezoidal threads and what are the disadvantages of
of active coils; (iv} total number of active coils;
square threads with trapezoidal tlrreads ? 6
(v) solid length (vi) free length (vii) pitch of the coil. 8
(c) A double-threaded power screw, with ISO metric
(c) A mild steel ~haft transmits 20 kW at 200 r.p.m. It
trapezoidal threads is used to raise a load of 300 kN.
carries a central load of 900 N and is simply
The nominal diameter is l 00 mm and the pitch is
supported between the bearings 2-5 metres apart.
12 mm. The coefficient of friction at the screw threads
Determine the size of the shaft, if the allowable shear
is 0.15. Neglecting collar friction, claculate (i) torque
stress is 42 MPa and the maximum tensile or
required to raise the load (ii) torque required to lower
compressive &tress is not to e.xceed 56 MPa. What
the load; and (iii) efficiency of the screw. lO
size of the shaft will be required, ifit is subjected to
4. (a) Distinguish between the circumferential stress and gradually applied loads '! 10
longitudinal stress in a cylindrical shell, when subjected
6. (a) Define fonnative or virtual number of teeth on a
to internal pressure. 5
heli<:al g1;;ar. D..:ri \/(' 1h,: express,ion used t.o obtain ii.s
( b) Describe the procedure for designing a lozenge joint. 5 vah1e. 5

S'l'.FIAN:MC407/PR407/l5il0) ( 2) ( Turn r>vrr )

45
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( b) Explain different causes of gear tooth tailures and (b) Explain the following terms as applied to journal
suggest possible remedies to avoid such failures. 5 bearings: 4

(c) State any two advantages and disadvantages of dt.-cp (i) Bearing characteristic number and
groove ball bearing. 4 (ii) Bearingmodulus.

(d) A 80 mm longjoumal bearing supports a load of2800 (c) Explain the phenomenon of interference in involute
N on a 50 mm diameter shaft. The bearing has a gears and what are the conditions to be satisfied in
radial clearance of0,05 mm and the viscosity of the order to avoid interference ? Also discuss the design
oil is 0-021 kg/m-s atthe operating temperature. If the procedure for spur gears. 5+ 5
bearing fa capable of dissipating 80 J/s, determine the
GroapC
maximum safe SptX~<l 6
9. Answer the following in brief: 10 X 2
7. (a) Discuss the various important parameters necessary
for the selection of a particular drive for power (,) What do you understand by Shear stress and Shear
transmission. 4 strain?

( b) Write equations showing the ~1rength ofthe cottc<r joint (ii) Discuss briefly thermal stresses.
for the most probable methods of failure. 6 ( iii) Different types of rivet materials.
(c) A plane c.lutch having a single driving plate with (iv) State two important reasons for adopting involute
contact surfaces on each side is required to transmit curves for a gear tooth profile.
I 10 kW at l l O rpm. The outer diameter of the
{v) Examine hydrodynamic lubrication.
contact sl.llface is to be 300 mm. The coefficient of
friction is 0·4 (a) Assuming a uniform pressure of (vz) Define Sommerfeld number.
0.17 N/mm2; determine the inner diameter of the (vi,) Define dynamic load carrying capacity of rolling
friction surfaces. (b)Alisuming the same dimensions contact bearing.
and the same total axial thrust, detennine the
(viii) State some applications of bevel gear.
ma.ximum torque that can be transmitted and the
maximum intensity of pressure when uniform (ix) What are the advantages ofV-belts over flat belts?
wear conditions have been reached. 10 (x) Explain transverse fillet weld.
3. (a) What are the &fforcnt important factors in brake
design? Dioouss the different types of brakt.-s giving
at least one pracfr;al eXilmp!t, for each. 6

S' 17:'i'AN:MC:4071I'R40'7 (1500) ( 4 ) !Cont:111wd) ST':7AN:MC4071PR407 (1500) ( 5 ) AG-7,700

46
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