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# DEPARTMENT OF MECHANICAL ENGINEERING

S7 ME
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MACHINE DESIGN - I

Assignment No. 2

To be submitted on 28-09-2012

A mild steel connecting rod of square cross section is subjected to a completely reversed axial load of 120 kN. Suggest a suitable size of the rod using a factor of safety of 2.4, if the suggested life of the rod is 2105 cycles only. Take a surface finish factor of 0.8. Choose the other factors suitably. A hot rolled steel shaft 600 mm long and supported between bearings at its ends, is subjected to a torsional load that varies from 2.8 kNm clockwise to 1.4 kNm anticlockwise and a central concentrated load that varies from 3.5 kN to 1.8 kN. The shaft is of uniform cross section. Determine the required shaft diameter if the material has an ultimate strength of 640 MPa and a yield strength of 420 MPa. Assume a factor of safety of 2.2. Find the value of factor of safety if the part in figure-1 is made of C-40 steel and of uniform thickness of 40 mm.
10040 kN

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## 60 mm 10 mm radius 20 mm dia 100 mm

Figure-1 4.

Figure - 2

A simply supported beam 40 mm diameter and 600 mm long is subjected to a central concentrated load which varies from W to 3W. The material of the beam is cold rolled steel. Determine the maximum value of W, if the design factor is to be 2.4. Use a size factor of 0.85 and a surface finish factor of 0.9. The general proportions of a shaft for an idler pulley with a constant overhung load are shown in figure-2 with dimensions in mm. The material is an oil-quenched and normalized alloy steel with ultimate tensile strength of 810 MPa and yield strength of 500 MPa. From the right, let the diameters be 85, 100 and 120 mm. All surfaces are machined. The fillet radius at a-a is restricted by ball bearing to 2 mm, but the fillet radius at b-b can be more generous, with perhaps r/d = 0.075. Estimate the factors of safety at planes a-a and b-b. Assume the pulley to be keyed to the shaft. Bearing reactions R1 and R2 are exerted on the shaft shown in figure3, which rotates at 1200 r.p.m. and supports a 45 kN bending force. Use S.A.E. 1095 steel. Specify the diameter d using a design factor of n = 1.6 for a life of 50 minutes. The surfaces are machined.

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Figure3 Figure-4 The cover of a pressure vessel is held in place by ten M20 bolts. The internal pressure is 1.5 MPa and the effective area of the cover exposed to the pressure is 0.2 m2. The ratio of the stiffness of the bolts to the connected parts is 4. Initially (before the pressure is applied), each bolt is tightened to 30 kN. (a) Will the joint separate as a result of the load due to internal pressure? (b) If the joint does not separate, determine the tensile stress in each bolt due to the axial load. A mild steel bracket is connected to a vertical member by eight bolts of equal diameters, as shown in figure-4. A vertical force of 50 kN acts in the plane of the bolts at a horizontal distance of 300 mm from the centre of the bolt arrangement. Suggest the suitable size of the bolts for a permissible shear stress of 55 MPa.

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Figure-5 9.

Figure-6

A 10mm25mm (cross-section) bar is welded to a 100mm diameter cylinder and the cylinder itself is welded to a frame on its vertical face, as shown in figure-5. Both the cylinder and the bar are kept horizontally and a vertical load of 600 N is applied at the end of the bar, as shown. Determine the required sizes of the 45 fillet welds.

10. Find the value of the maximum stress in the welded joint of figure-6. The weld extends across the top and along the vertical edge. 11. The following data apply to the machinists clamp shown in figure7. Outside diameter of the screw = 12 mm Root diameter = 10.16 mm Pitch (single thread) = 1.5 mm Collar friction radius = 5 mm Collar friction coefficient = 0.15 Screw friction coefficient = 0.15 Assume that the machinist can comfortably exert a maximum force of 120 N on the handle. Determine (a) the clamping force developed between the jaws of the clamp (b) the efficiency of the clamp (c) the torque in the screw body at section A-A. 12. A steel screw driving a bronze nut is to develop an axial load of 300 kN in an extrusion press. The screw has an outside diameter of 100 mm and a single square thread (depth = pitch) with a lead of 16 mm. The length of nut is to be chosen so that the bearing pressure between screw and nut threads will not exceed 28 MN/m2. Determine a suitable nut length.

Figure7