Design of Machine Elements-I 10ME52

V T U - QUESTION PAPERS SOLUTION

UNIT 1
INTRODUCTION
1. Identify the following engineering materials giving specifications:
i) FG350.
ii) FeE300.
iii) C35Mn75.
iv) X20Cr18Ni2. (June/July 2014)
2. Point in a structural member is subjected to plane state of stress
Determine the following:
i) Normal and tangential stress intensities at a angle of θ = 45°
ii) Principal stresses σ1, and σ2 and their directions.
iii) Maximum shear stress and its plane. (June/July 2014)

3. Draw stress - strain diagram for mild steel subjected to tension. Explain the significance of
salient points. (Dec/Jan 2015)

4. What are the basic requirements of machine elements? Explain briefly. (June/July 2015)
5. What are the factors to be considered for selection of material for a machine component?
(June/July 2015)

6. A hollow shaft of 40mm diameter and 25mm inner diameter is subjected to a twisting moment
of 118 N-m, a axial thrust of 9806 N and a bending moment of 79 N-m. Calculate the maximum
compressive and shear stresses. (Dec/Jan 2016)

7. For the stress-element shown in Figure, find the principal stresses and directions.

(June/July 2016)

8. Write a note on uniform strength (Jun/July2016)

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Design of Machine Elements-I 10ME52

UNIT 2
DESIGN FOR STATIC AND IMPACT STRENGTH

1. A round stepped shaft is made of brittle material cast iron FG 260 and subjected to a bending
moment of 15 N-m as shown in Figure. The stress concentration factor at the fillet is 1.5.
Determine the following:

i) Step diameter.

ii) Magnitude of stress at fillet.

iii) Factor of safety. (June/July 2014)

2. Derive an expression for impact stress in a bar of cross section' A' and length 'L' due to the
impact of a load 'W' falling from a height 'h' on the bar, as shown in Fig.

(June/July 2014)

3. The brasses of an automobile engine connecting rod have worn, so as to allow play which
gives shock loading equivalent to a weight of 5886 N falling through a height of 0.2 mm. The

connecting rod is 250 mm long and has a cross sectional area of 3x10 -4 m 2. Determine the
stress induced in the connecting rod. Compare the maximum stress induced with that of a static load
of 5886 N. (Dec/Jan 2015)

4. A bolt is subjected to a direct tensile load of 30kN and a transverse shear force of 15 kN.
Material of the bolt has a normal stress of 350 MPa at yield and Poisson's ratio of 0.25.
Compute the root diameter of the bolt according to:

i) Maximum shear stress theory of failure and

ii) Von-mises criterion for failure.

Hence suggest suitable size of the bolt. Take a value of 3 for factor of safety. (Dec/Jan 2015)

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Design of Machine Elements-I 10ME52

5. In a plate of C45 steel (σ y = 353 MPa) subjected to a system of loads, following stresses are
induced at critical point: σx =150 N/mm2, σ y = 100 N/mm2 a nd τ xy = 50 N /mm2. Find t he
factor of safety according to,
i. Maximum normal stress theory. ii. Maximum shear stress theory.
iii. Distortion energy theory. (June/July 2015)
6. Determine the safe load that can be carried by a bar of rectangular cross section shown in Fig.
Limiting the maximum stress to 130 MPa taking stress concentration into account.
(Dec/Jan 2016)

7. An unknown weight falls through 20 mm as to a collar rigidly attached to the lower end of a
vertical bar 2 meter long and 500 sq mm section. If the maximum extension is 2 mm, what is the
corresponding stress and the value of unknown weight? Take E = 200 GPa. (June/July 2016)

8. A weight 600 N drops through a height of 20 mm and impacts the center of 300 mm long
simply supported circular cross section beam. Find the diameter of the beam arid the maximum
deflection, if the allowable stress is limited to 90 MPa. Neglect the inertia effect and take E = 200
GPa. (June/July 2016)

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Design of Machine Elements-I 10ME52

UNIT 3
DESIGN FOR FATIGUE STRENGTH

1. Derive Goodman's equation. (June/July 2014)

2. Explain cumulative fatigue damage. (Dec 2014)

3. A circular bar of 500 mm length is supported freely at its two ends. It is acted upon by a
central concentrated cyclic load having a minimum value of 20 kN and a maximum value of 50
kN. Determine the diameter of bar by taking a factor of safety of 2, size effect of 0.85, surface
finish factor of 0.9. The material properties of bar are given by: ultimate strength of 650 MPa,
yield strength of 500 MPa and endurance strength of 350 MPa.

(June/July 2015)

4. A Cantilever beam made of 35C8 steel (σut = 540MPa) is subjected to a completely reversed
load of 1000 N as shown in Figure. The notch sensitivity factor 'q' at the fillet can be taken as 0.85
and expected reliability is 90%. Determine the diameter of the beam for a life cycle of 10000
cycles. (Dec 2015)

5. A cantilever beam made of cold drawn C30 steel (συτ= 550 MPa and σyτ = 470 MPa)
subjected to load which varied from - F and 3F, as shown in Figure. Determine the maximum load
that these members can withstand for an indefinite life using a factor of safety '2'. The stress
concentration factor effect has to be considered with notch sensitivity of 0.9. Analyze at the fillet
section only. (June/July 2016)

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Design of Machine Elements-I 10ME52

6. A hot rolled steel rod is subjected to a torsional load that varies from 330 N-m, clockwise to
110 N-m counter clockwise and an applied bending moment varies from + 440 N-m to -
220 N-m. the rod is of uniform cross section. Determine the required rod diameter. The
material has an ultimate tensile strength of 550 MPa and yield strength of 410MPa. Design based
as a factor of safety of 1.5. Take the endurance limit as 1 (June/July 2016)

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Design of Machine Elements-I 10ME52

UNIT 4
THREDED FASTENERS
1. Write a note on bolt of uniform strength (Jun/July2014)

2. A wall bracket is attached to a wall by means of 4 identical bolts, two at A and two at B, as
shown in Fig. Assuming that the bracket is held against the wall and prevented from tipping about
C, by all four bolts, and using an allowable stress in the bolt as 35 MPa, determine the size of bolts
on the basis of maximum principle stress theory, selecting ISO, metric threads of not than 1.5 mm
pitch. (Jun/July2014)

3. An M20x2 steel bolt of 100mm long is subjected to impact load. The energy absorbed by the
bolt is 2 N-m,

i) Determine the stress in the shank of the bolt if there is no threaded portion between the nut
and bolt head.

ii) Determine the stress in the shank if the entire length of the bolt is threaded.

Assume modulus of elasticity for steel as 206 GPa. (Dec 2014)

4. Determine the size of the bolts for the loaded brackets shown in Fig, if the allowable Tensile
stress in the bolt material is limited to 80 MPa. (Jun/July2015)

5. A MIO steel bolt of 125 mm- long is subjected to an impact load. The kinetic energy
absorbed by the bolt is 2.5 Joules. Determine (i) Stress in the shank of the bolt if there is no
threaded portion between the nut and the bolt head, (ii) Stress in the shank of the area of the shank
is reduced toof the bolt is threaded. (Dec2015)

6. A bolt is subjected to initial loading of 5 kN and final tensile load of 9 kN. Determine the
size of the bolt, if the allowable stress is 80 MPa and K = 0.05. (Jun/July2016)

7. A Flange bearing as shown in Figure is fastened to a frame by means of 4 bolts, spaced

equally on a 500mm bolt circle. The dia of the bearing flange in 650mm and a load of 400 kN

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Design of Machine Elements-I 10ME52

acts at a distance of 250mm from the frame. Determine the size of bolt, taking allowable tensile
stress in the bolt material as 60N/m2. (Jun/July2016)

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Design of Machine Elements-I 10ME52

UNIT 5
DESIGN OF SHAFTS
1. A transmission shaft running at 500 rev/min is supported on bearings 800 mm apart. 20 KW
power is supplied to the shaft through a 450 mm dia pulley which is located 400mm to the
further transmits this power to a spur gear of 300 pitch circle diameter, which is located at
400mm to the right of left bearing. The gear has 20° involute teeth and ratio of belt tensions is
3:1. The gear drives another gear which is place directly above the shaft. The gear drives another
gear which is places directly above the shaft. The gear and pulley are keyed to the shaft.
Selecting the Material as steel having σu,= 700 MPa and σyt= 460MPa as per ASME code,
determine of shaft. Assume shock factor for bending and torsion as 1.5. (June/July 2014)

2. The standard cross- section of a flat key, which is fitted on a 50 mm diameter shaft is 16 x 10
mm. The key is transmitting 475 N-m torque from the shaft to the hub. The key is made of
commercial steel for which yield strength in both tension and compression may be taken as
230 N/mm2. (Dec 2014)

3. A hollow propeller shaft of 0.6 m outside diameter and 0.3 m inside diameter is used to drive a
propeller of a marine vessel. The shaft is mounted on bearings 5m apart and it transmits 6 MW
power at 100rpm. The maximum axial propeller thrust is 600 kN and shaft weighs 60 kN.
Determine i) Maximum shear stress developed in the shaft (June/July 2015)

4. If a shaft and key are made of same material, determine the length of the key required in terms of
shaft diameter, taking key width and key thickness. Assume keyway factor as 0.75 (Dec 2015)

5. A horizontal steel shaft, supported on bearings "A" at the left end and "B" at the right end,
carries two gears "C" & "D", located at distances 250 mm and 400 mm respectively, 'from the
center lines of left and right end bearings'. The pitch diameter of gear C is 600mm and that of
gear D is 200 mm. The pressure angle is 20°. The distance between the center lines of the
bearings is 2400 mm. The shaft transmits 20 kW power at 120 rpm, The power is delivered to the
shaft at gear C and is taken out a gear D in such a manner that the tooth pressure F tc and F td are
100 MPa in tension and 56 MPa in shear. The gear C and D weigh 950 Nand 350 N
respectively. Take Cm = 1.5 and CT = 1.2 (June/July 2016)

6. Prove that a hollow shaft is stronger and stiffer than a solid shaft of same length, weight and
material. (June/July 2016)

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Design of Machine Elements-I 10ME52

UNIT 6
COTTER AND KNUCKLE JOINTS, KEYS AND COUPLINGS
1. The standard cross- section of a flat key, which is fitted on a 50 mm diameter shaft is 16 x 10
mm. The key is transmitting 475 N-m torque from the shaft to the hub. The key is made of
commercial steel for which yield strength in both tension and compression may be taken as 230
N/mm. Determine the minimum length of key required if the factor of safety is 3. (June/July 2014)

2. It is required to design a rigid type flange coupling to connect two shafts. The input shaft
transmits 37.5 KW at 180 rev/Min to the output shaft through the coupling. The starting torque
is 50% higher than the rated torque. Select material for flanges as cast iron FG200
(σut=200MPa) with a factor of safety 6, material for shafts as carbon steel with (σyt=380MPa), with
a factor of safety 2.5, material for key and bolts may be taken as steel with (σyt=400MPa in tension)
and (σyc=600MPa in compression) respectively and a factor of safety 2.5. Design the coupling and
given dimension. (Dec 2014/Jan 2015)
3. If a shaft and key are made of same material, determine the length of the key required in
terms of shaft diameter, taking key width and key thickness. Assume keyway factor as 0.75.
(Jun/July2015)

4. Design a rigid flange coupling to transmit 18kW at 1440 rpm. The allowable shear stress in the
cast iron flange is 4 MPa. The shaft and keys are made of AISI 1040 annealed steel with ultimate
strength and yield stress valued as 518.8 MPa and 353.4 MPa, respectively. Use ASME code to
design the shaft and the key. (Dec2015/Jan2016)

5. Design a cast iron flanged couplings for a steel shaft transmitting 100 kW at 250 rpm. Take the
allowable shear stress for the shaft as 40 N/mm2. The angle of twist is not to exceed 1° in a length
of 20 diameters. Allowable shear stress for the bolts is 13 N/mm 2. The allowable shear stress in
the flange is 14 N/mm2. For the key shear stress is 80 N/mm2. (June/July2016)

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Design of Machine Elements-I 10ME52

UNIT 7
RIVETED AND WELDED JOINTS
1. Design a double riveted lap joint with zig-zag riveting for 13 mm thick plates. The working
stresses to be used are a = 80 MPa; τ = 60 MPa; σc= 120 MPa. State how the joint will fail and
find the efficiency of the joint. (June/July 2014)
2. A bracket carrying a load of 15 kN is to be welded as shown in Figure. Find the size of the
weld required if the allowable shear stress is not to exceed 80 MPa. (June/July 2014)

3. Design a double riveted but joint with two cover plates for the longitudinal seam of a boiler
shell 1.5 M in diameter subjected to a steam pressure of 0.9 MPa. Assume joint efficiency as
75%. Allowable stress in tension for the plate 83 MPa in compression 138 MPa and stress in
rivets may be assumed as 55 MPa. Assume chain riveted joint. (Dec 2014/Jan 2015)

4. A circular shaft 50 mm in diameter is welded to a support by means of a fillet weld and loaded as
shown in Figure. Determine the size of weld of the permissible shear stress in the weld is
limited to 100 MPa. (June/July 2015)

5. A bracket is supported by means of four rivets of dame size as shown in Figure. Determine the
diameter of the rivet if the maximum shear stress in the rivet is 90 N/mm2. (Dec 2015)

6. Determine the maximum normal stress and the maximum shear stress in the weld shown in
Figure.

(June/July 2016)

7. Design a double riveted butt joint with two cover plates for the longitudinal beam of a boiler
shell 1.5 m in diameter subjected to a steam pressure of 0.95 N/mm 2. Assume an efficiency of
75%, allowable tensile stress in the plate of 90 N/mm2, allowable crushing stress of 140 N/mm2
and an allowable shear stress in the rivet of 50 N/mrn2. (June/July 2016)

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Design of Machine Elements-I 10ME52

UNIT 8
POWER SCREW
1. Derive the equation for maximum efficiency of square threaded screw. (June2014/June2015)

2. The cutter of a broaching machine is pulled by square threaded screw of 55 mm external

diameter and 10 mm pitch. The operating nut takes the axial load of 400 N on a flat surface of 60
mm and 90 mm internal and external diameters respectively. If the coefficient of friction is 0.15 for
all contact surfaces, determine the power required to rotate the not when the cutting speed is
6m/min. Also find the efficiency of the screw. (Dec 2014)

3. The lead screw of a lathe has single start ISO metric trapezoidal treads of 52mm nominal
diameter and 8mm pitch. The screw is required to exert as axial force of 2kN in order to drive the
tool carriage during turning operation. The thrust is carried on a collar of 100mm outer diameter
and 60mm inner diameter. The values of Coefficient of friction at the screw threads and collar
are 0.15 and 0.12 respectively. The lead screw rotates at 30 rev/min.

i) The power required to drive the screw

ii) The efficiency of the screw. (June/July 2015)

4. A weight. of 500 kN is raised at a speed of 6 m/min by a two screw rods with square threads of
50 x 8 cut on them. The the screw rods are driven through level gear drives by a motor.
Determine (i) The torque required to raise the load (ii) The speed of rotation of the screw rod
assuming the threads are double start (iii) The maximum stresses induced in screw rod.
(iv) The efficiency of screw drive. (v) The nuts for supporting the load (Dec 2015/Jan 2016)

5. A single start square-threaded power screw is used to raise a load of 120 kN. The screw has a
mean diameter of 24 mm and four threads per 24 mm length. The mean collar diameter is 40
mm. The coefficient of friction is estimated as 0.1 for both the thread and the collar. (i) Determine
the major diameter of the screw. (ii) Estimate the screw torque required to raise the load. (iii)
Estimate overall efficiency. (iv) If collar friction is eliminated, what minimum value of thread
coefficient is needed. (June/July 2016)

6. Write a note on power screw strength. (June/July2016)

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