ACT COLLEGE OF ENGINEERING AND TECHNOLOGY NELVOY DEPARTMENT OF MECHANICAL ENGINEERING SUB CODE: ME2303 SUB NAME: DESIGN

OF MACHINE ELEMENTS UNIT I STEADY STRESSES AND VARIABLE STRESSES IN MACHINE ELEMENTS TWO MARKS 1. Define: Factor of safety The ratio between maximum stresses to working stress is known as factor of safety. Factor of safety = Maximum stress / Working stress 2. Define endurance limit. Endurance limit is the maximum value of completely reversed stress that the standard specimen can sustain an infinite number (106) of cycles without failure. 3. What is impact load? If the time of load application is less than one third of the lowest natural period of vibration of the part, it is called an impact load. 4. What are the various phases of design process? (May 2010) I.Recognition of need, ii.Definition of problem iii.Synthesis, iv.Analysis and optimization v.Evaluation, vi.Presentation 5. What are the different types of loads that can act on machine components? a. Steady load. b.Variable load. C.Shock load d.Impact load. 6. What are the factors affecting endurance strength. The factors affecting endurance strength are i. Load ii. Surface finish iii. Size iv. Temperature
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v. Impact vi. Reliability

7. What are the types of variable stresses? a. Completely reversed or cyclic stresses b.Fluctuating stresses, c.Repeated stresses 8. Differentiate between repeated stress and reversed stress. Repeated stress refers to a stress varying from zero to a maximum value of same nature. Reversed stress of cyclic stress varies from one value of tension to the same value of compression. 9. What are the types of fracture? a. Ductile fracture b.Brittle fracture 10. Distinguish between brittle fracture and ductile fracture. In brittle fracture, crack growth is up to a small depth of the material. In ductile fracture large amount of plastic deformation is present to a higher depth. 11. Define stress concentration and stress concentration factor. Apl 09 Stress concentration is the increase in local stresses at points of rapid change in cross section or discontinuities. Stress concentration factor is the ratio of maximum stress at critical section to the nominal stress 12. Explain size factor in endurance strength. Size factor is used to consider the effect of the size on endurance strength. A large size object will have more defects compared to a small one. So, endurance strength is reduced. If K is the size factor, then Actual endurance strength = Theoretical endurance limit x K 13. What is Griffith theory. (Or) State the condition for crack growth.
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A crack can propagate if the energy release rate of crack is greater than crack resistance. 14. What are the modes of fracture? a. Mode I (Opening mode) Displacement is normal to crack surface. b.Mode II (Sliding mode) Displacement is in the plane of the plate. C.Mode III (Tearing mode) Out of plane shear. 15. What are the factors to be considered in the selection of materials for a machine element? I.Required material properties, ii.Manufacturing ease Iii.Material availability, iv.Cost. 16. What are various theories of failure? i.Maximum principal stress theory. ii.Maximum shear stress theory. iii.Maximum principal strain theory.iv.Distortion energy theory. v.Maximum strain energy theory. 17. List out the factors involved in arriving at factor of safety i.material properties, ii.nature of loads iii.presence of localized stresses, iv.mode of failures 18. Give some methods of reducing stress concentration. (Nov 08) i.Avoiding sharp corners, ii.Providing fillets. iii.Use of multiple holes instead of single hole iv.Undercutting the shoulder parts. 19. Explain notch sensitivity. State the relation between stress concentration factor, fatigue stress concentration factor and notch sensitivity. Notch sensitivity (q) is the degree to which the theoretical effect of stress concentration is actually reached. The relation is, Kf = 1 + q(Kt-1) 20. What are the factors that affect notch sensitivity?
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i. Material, ii. Notch radius, iii.Size of component iv.Type of loading, v.Grain Structure 21. What is the use of Goodman & Soderberg diagrams? They are used to solve the problems of variable stresses. 22. Define machinability It is the property of the material, which refers to a relative case with which a material can be cut. It is measured in a number of ways such as comparing the tool life for cutting different material 23. What is an S-N Curve? An S- N curve has fatigue stress on Y axis and number of loading cycles in X axis. It is used to find the fatigue stress value corresponding to a given number of cycles. 24. Define Ductility It is the property of the material enabling it to be drawn into wire, with the application of tensile force. It must be both strong and plastic. It is usually measured in terms of percentage elongation and reduction in area. (eg) Ni, Al, Cu 25. Define fatigue When a material is subjected to repeated stress, it fails at stresses below the yield point stress; such type of failure of the material is called fatigue. 26. What is curved beam? In curved beam the neutral axis does not coincide with the centroidal axis. 27. Give some example for curved beam. C frame, crane hook 28. What is principle stress and principle plane? A plane which has no shear stress is called principle plane the corresponding stress is called principle stress. 29. Write the bending equation. M/I = E/R = Fs/Y. M Bending moment
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I - Moment of intertia E - Youngs modulus R - Radius of the shaft Fs Shear stress Y - Distance from neutral axis 30. Write the torsion equation. T/J = C/L = Fs/R, T Torque , J - Polar moment of inertia C- Rigidity modulus Angle of twist L Length of the shaft Fs Shear stress R - Radius of the shaft 31.Differentiate the stress distribution in abar subjected to axial force and bending force Principal stress is used to know about design stress adopted for a machine componentsubjected to two types of stresses combinely 32. For ductile material , which of the strength is considered for designing APL 08 (a)Component subjected to static loading (b) Component subjected to fatigue loading Tensile stress is considered for static loading Compressive stress is considered for fatigue loading. 33.Mention some standard codes of specification of steels Steels are specified by x.C.y where x- number indicating 100 times the average percent of carbon and y- number indicating 100 times the average percent of manganese. 34.How will you account for stress concentration in design of the machine elements Mathematical method based on theory of plasticity Experimental method based on theory of photo elasticity. 35. What you mean by optimum design? Optimum design is the process of maximizing the desired quantity or minimizing the undesired one.It is the process used to increase the productivity.
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36. State Rankines theory(Nov 07) Rankines theory states that when a copmponent is subjected to biaxial or uniaxial stresses the failure occurs when the maximum normal stress is equal to the tensile yield strength of the material in a simple tension test. 37. What is gerber theory?Nov 09 Gerber parabola joins the endurance stress and ultimate stress like goodman line. According to Gerber method, the relationship between m.a,u and -1 is given by a = -1[1-(m/u)] 38.What are the factors that govern selection of materials while designing a machine component? Strength & stiffness Surface finish and tolerances Manufacturability Ergonomics and aesthetics Working atmosphere

39.Write soderberg equation for machine component subjected to (a) Combination of mean and variable torques (b) Combination of mean and variable bending moments. eq = y/n =m+kf*a*y/-1 eq = y/n = m+kf*a*y/-1 40. State three conditions where tap bolts are used.

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 One of the parts being joined has enough thickness to accommodate a threaded hole. Insufficient apace for a nut. Material is strong enough so that the threads have long life.

41.What are the reasons of replacing riveted joint by welded joint in modern equipment? Material is saved in welding joints and hence the machine element will be light if welded joints are used instead id riveted joints. Lead proof joints can be easily obtained by welded joints compared riveted joints.

42.What is the effect of increase in wire diameter on the allowable stress value? The direct shear stress (1/d) and torsional shear stress (1/d). Hence, increase in wire diameter reduces that allowable stress value.

43.What type of stresses is produced in a disc flywheel? Tensile stress due to centrifugal force Tensile bending stress caused by the restraint of the arms and The shrinkage stresses due to unequal rate of cooling of casting.
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44.For a journal bearing, the maximum operating temperature must be less than 80c.why? Temperature rise will result in the reduction of the viscosity as the oil used in the bearing. This would lead to metal to metal contact, thereby affecting the bearing performance & life.

45.Why is piston end of a connecting rod kept smaller than the crank pin end? The piston end of the connecting rod experiences less bending moment than the crack end. Hence, on the basis of beam of uniform strength, the piston end of the connecting rod is smaller. 16 MARKS 1. A medium force fit on a 50mm shaft requires a hole tolerance of 0.025mm and a shaft tolerance of 0.016mm. The maximum interference is to be 0.042mm. How will you dimension the hole and the shaft, if hole deviation is H? Dec 2010 Given data: Basic diameter of shaft, d=50mm Hole tolerance = 0.025mm Shaft tolerance = 0.016mm Maximum interference = 0.042mm Hole deviation = H
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Solution: Hole: Since this is a H system, the hole has the basic size. In other words, lower limit of hole = basic size Dmin = 50mm Hole tolerance = Dmax- Dmin = 0.025 Dmax = 0.025+ Dmin = 0.025+50=50.025 The hole is dimensioned as 50-0.000+0.025 Shaft: Maximum interference = max. dia of shaft (d max)Min.dia of hole (Dmin) 0.042 = d max-50 Shaft tolerance = d max- d min = 0.016mm (or) 50.042-d min = 0.016 (or) d min = 50.042-0.016 = 50.026mm The shaft is dimensioned as 50-0.000+0.025

2. Explain the following with mathematical expressions. Maximum principal stress theory; Vonmises stress theory. MAY 08 Maximum principal stress theory: This theory states that the failure of the mechanical component occurs when subjected to biaxial or uniaxial stresses, when the maximum principal stress reaches the ultimate or yield strength of the material.according to this theory, The failure occurs when, Su or Sy. If F.O.S is considered then,
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 (Su or Sy)/Nf. Where, -max principal stress, Su- Ultimate stress, Sy- yield strength of the material. Von-mises stress theory: This theory is also known as Distortion energy theory. This theory states that the failure of the mechanical component occurs when subjected to biaxial or uniaxial stresses, when the distortion energy per unit volume reaches the limiting distortion energy per volume at the yield point.acc to this theory, [1-12+2] Syt/Nf Where Syt Yield tensile strength of the material. 3. A cost iron pulley transmits 12 kW at 330 rpm. The diameter of the pulley is 1.3 m and it has four straight arms of elliptical cross section in which the major axis is twice the minor axis.Determine the dimensions of the arm if the allowable bending stress is 18 MPa. MAY 08 Given data: R=D/2=1300/2 =650 mm Power=12kW, n=330 rpm , No of arms = 4, a= 2b, b = 18 n/mm Solution: Torque actin on pulley (T): P =2nT/(60*1000) 12 =2 * 330*T/60000 , T=347.247Nm. Force on each arm(F) : F= T/NR= 347247/(4*650) F = 133.56 N Maximum bending moment M: M= F(R-rh) , where rh= radius of hub, as rh << R, then = F*R
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M = 86811.75 Nmm Dimensions of arm cross section: Z= /32 ab for elliptical cross section, Z= b/8, also b =M/Z 18= 86811.75/( b/8)), b = 12281.35, b= 23.07 mm a = 2b= 23.07*2 a =46.2mm. 4. A shaft of 760 mm length is simply supported at its ends. It is subjected to a central concentrated cyclic load that varies from 12 to 36 kN. Determine the diameter of the shaft assuming a factor of safety of 2, size correction factor of 0.8, and surface correction factor of 0.85. The material properties are ultimate strength = 500 MPa; yield strength = 280 MPa; and endurance limit = 250 MPa. Fatigue stress concentration factor = 1.5. May 08 Given data: L= 760 mm, Fmax= 36 kN, Fmin =12 kN, Nf= 2 Kb= 0.8, Ka= 0.85, Kf=1.5, Sut= 500 N/mm Syt=280 N/mm , Se= 250 N/mm Solution: Ke = 1/Kf Ke =1/1.5= 0.6667 Se= Ka.Kb.Kf.Se = 0.85*0.8*0.6667*250 = 113.33 N/mm. Mean stress and stress amplitude: M= F/2 * L/2 Mmax= 36000/2*760/2 =68.4 10 Nmm
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Mmin = 12000/2*760/2 = 22.8 10 Nmm (b)max = 32 Mmax/(d)=32*68.4 10/ d (b)min = 32 Mmax/(d)=32*22.8 10/ d (b)m= ((b)max+(b)min) /2 = 464.45 10/d N/mm (b)a= ((b)max-(b)min) /2 = 232.2 10/d N/mm Using modified Goodman relation, Sut/Syt + Sa/Syt =1 Also, Sm/Syt + Sa/Syt = Sm/Sut + Sa/Se Subsituting and solving , we get, Sa/Sm= 0.3 Also, Sm/Sut + Sa/Se =1 (464.45 10/d)/500 + (232.2 10/d)/113.33 =1/2, considering factor of safety. Solving this equation we get, d =53 mm.

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UNIT II Design of Shafts and couplings TWO MARKS 1. Define the term critical speed. The speed, at which the shaft runs so that the additional deflection of the shaft from the axis of rotation becomes infinite, is known as critical or whirling speed. 2. What are the factors considered to design a shaft? i.strength, ii.stiffness 3. What is key? A key is device, which is used for connecting two machine parts for preventing relative motion of rotation with respect to each other. 4. What are the types of keys? i.Saddle key, ii.Tangent key, iii.Sunk key iv.Round key and taper pins 5. What is the main use of woodruff keys? A woodruff key is used to transmit small value of torque in automotive and machine tool industries. The keyway in the shaft is milled in a curved shape whereas the key way in the hub is usually straight. 6. List the various failures occurred in sunk keys. 1.Shear failure 2.Crushing failure

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7. What is the function of a coupling between two shafts? Couplings are used to connect sections of long transmission shafts and to connect the shaft of a driving machine to the shaft of a driven machine.

8. Under what circumstances flexible couplings are used?Nov 08, Nov 09 They are used to join the abutting ends of shafts when they are not in exact alignment. They are used to permit an axial misalignment of the shafts without under absorption of the power, which the shafts are transmitting. 9.What are the purposes in machinery for which couplings are used? i.To provide the connection of shafts of units those are manufactured separately such as motor and generator and to provide for disconnection for repairs or alterations. ii.To provide misalignment of the shafts or to introduce mechanical flexibility. iii.To reduce the transmission of shock from one shaft to another. iv.To introduce protection against over load. 10.What are the main functions of the knuckle joints? It is used to transmit axial load from one machine element to other. 11. Why a hollow shaft has greater stiffness and strength than solid shaft of equal weight?April 08 For same weight, the moment of inertia as well as polar moment of inertia of hollow shaft is higher than the solid
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shaft. Therefore the strength,stiffness and rigidity are higher for hollow shaft. 12.Why is maximum shear stress used for shaft The shaft is made of ductile material so, the maximum shear stress is used for finding thefailure. 13.What types of stresses are developed in the key? Direct shear stress and Crushing or compressive stresses are developed in the key. 14.Differentiate between keys and splines S.N KEYS SPLINES o 1 It is used on the shafts to The Splines are the multiple secure the rotating keys which are made integral elements like gears pulleys with the shafts or sprockets to prevent the relative motion between them 2. Keys prevent the relative Splines prevent the relative rotary as well as the axial rotary motion but permits the motion between the shaft axial motion between the and hub. shaft and hub 3. Torque transmission Torque transmission capacity capacity of key is moderate of splines is high. 4. It is used in couplings to The splines are used in secure the gears pulleys automobile gear boxes and and couplings or sprockets machine tool gear boxes. to the shaft. 15. What is the significance of slenderness ratio in shaft design?Nov 08 The higher slenderness ratio will have the following effects on shafts: (i) If the shaft is subjected to compressive force, the higher slenderness ratio will increase the possibility of buckling failure
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(ii) The higher slenderness ratio will increase the torsional and lateral deflection on the shaft. 16.What do you mean by stiffness and rigidity with reference to shafts? Stiffness is the resistance offered by the shaft for twisting and rigidity is the resistance offered by the shaft for lateral bending.

17.Suggest suitable couplings for Shafts with parallel misalignment Shafts with angular misalignment of 10 Shafts in perfect alignment. Shafts with parallel misalignment Flexible coupling such as spring coupling can be used for shafts with parallel misalignment Shafts with angular misalignment of 10 Universal coupling is suitable for shafts with angular misalignment of 10 Shafts in perfect alignment Rigid coupling can be used for shafts in perfect alignment. 16 MARKS
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1.Design a bushed-pin type of flexible coupling to connect a pump shaft to a motor shaft transmitting 30 kW at 900 rpm. The overall torque is 15% more than mean torque. The material allowable properties are as follows : (in crushing for shaft and key material) = 80 MPa (in shear for shaft and key material) = 40 MPa (in shear for cast iron) = 15 MPa. Bearing pressure for rubber bush = 0.8 MPa Material of the pin as same as that of shaft and key May 08 Given data: p =30 kW; n = 900 rpm; Tmax = 1.15 Tmean Solution: P =2 nT/(60*10 Tmax=1.15*318.31 = 366.06 Nm max = 16 Tmax /d 40 = 16* 366056/ d d = 40 mm; Design of key: From PSGDB P.NO :5.21, for d= 40 mm; W= 12 mm and h= 8 mm, l= 1.5 d=1.5*ho =60 mm, crushing of key : c = (Tmax/d/2)/(h/2*l) subsitituting the values we get l =91.51 =92 mm Shearing of key : = (Tmax/d/2)/wl Solving this equation we get l = 57.19 =58 mm Taking larger value ,l=92 mm Design of hub: Length of hub: l =92 mm outer dia of hub, D=2d D=2*40=80 mm Torsional sheat stress in hub: h= 16 Tmax/(D(1-K4)) h= 3.88<14 N/mm Design of flange: Thickness of flange =0.5 d = 0.5*40 =20 mm Thickness of protective flange : 0.25 d=10 mm
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Direct shear stress induced: f = Tmax/D/2/Dtf = 2*366056/ Dtf = 1.82 < 14N/mm,Hence safe. Design of pin: For d= 40 mm, no of pins, N = 4 Nominal dia of pin: db = 0.5d/N =10mm 2.A solid shaft of diameter d is used in power transmission.Due to modification of existing transmission system, it is required to replace the solid shaft by a hollow shaft of the same material and equal strength in torsion. If the recommended weight of the hollow shaft per meter length is half of the solid shaft, determine the diameter of the hollow shaft in terms of d. Dec 2009 Solution For solid shaft: max = 16T/d T = *max* d/16 . eqn(1) For hollow shaft : max = 16T/ do[1-k4] = 16T/ do[1- (di/do)4] = 16Tdo/[do4 - di4] T = max [do4 - di4]/ 16do.eqn(2) Equal strength solid and hollow shaft: *max* d/16 = max [do4 - di4]/ 16do di4 = do4-dod .eqn (3) Weight of solid and hollow shafts: Weight of solid shaft per metre length : Ws = dg/4 ..eqn(4) Weight of solid shaft per metre length : Wh = [do - di]g/4..eqn(5) Wh =1/2 Ws From eqn (4) and eqn (5) , we get [do - di]g/4 = dg/4
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do - di = d/2 di = do - d/2 di4 = do4 - do d2 + d4/4 eqn(6) Outer diameter of hollow shaft From eqn (3) and eqn (6) do4-dod = do4 - do d2 + d4/4 do d2 - dod - d2/4 = 0, solving the above eqn we get , do = d2( d2 + d2)/2, = [d2 + 2 d]/2 do = [ (1 + 2)/2]d 3.Design a rigid type of flange coupling to connect two shafts. The input shaft transmits 37.5kW power at 180 rpm to the output shaft through the coupling. The service factor for the application is 1.5. Select suitable material for various parts of the coupling. NOV 2010 Given data: Power, p = 37.5kW = 37.5*10 W Speed, N =180 rpm Service factor = 1.5 Solution: Diameter of shaft, d: Torque transmitted by the shaft, Mt Mt = 1.5*p*60/2N = 1.5*37.5*10*60/2*180 = 2984.15 N-m = 2.984*106 N-mm ..(1)

Assume that the shaft key and bolts are made of mild steel which is having Allowable shear strength for steel = 60/mm Allowable crushing strength for steel = 120 N/mm Torque transmitted by the shaft, Mt
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Mt = /16*s*d From eqn (1) and (2) 2.984*106

=

(2)

/16*s*d

D= 63.27mm Say, diameter of the shaft, d = 64mm Outside diameter of hub, D D = 2d =2*64 =128mm Pitch circle diameter of bolts, D1 D1 = 3d= 3*64 = 192mm

Outer diameter of flange, D2 D2 = 4d = 4* 64 256mm

Length of hub, L L = 1.5d = 1.5*64 = 96mm

Thickness of flange, tf Tf = 0.5d =0.5*64 = 32mm

Design of hub: Assume that the hub is made of cast iron the allowable shear strength of cast iron is 15N/mm. We know that Since h is less than the allowable shear stress 15N/mm. Hence the design is safe. Design of key: From PSGMB 5.16, corresponding to d = 64mm Width of the key, b = 18mm
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Height of the key, h = 11mm Length of the key, l = 96mm (same as hub length) Check for shear

This is less than the allowable value 60N/mm. Hence the design is safe. Check for crushing Since, ck is more than the allowable value of 90N/mm. The design is not safe. Hence increase the height of the key. 2.984*106
=

96*h/2*120*64/2

H = 16.18mm, say the revised height of key, h 17mm Design of flange Since h is less than the allowable shear stress 15N/mm. Hence the design is safe. Diameter of bolt, db Torque transmitted by the bolts due to shear stress Assume number of bolt, n = 4 Say, diameter of bolt, db = 13mm Check for crushing Since cb is less than 120N/mm. Hence, the design is safe. 4.Design a bushed-pin type of flexible coupling to connect a pump shaft to a motor shaft
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transmitting 30 kW at 900 rpm. The overall torque is 15% more than mean torque. The material allowable properties are as follows : (in crushing for shaft and key material) = 80 MPa (in shear for shaft and key material) = 40 MPa (in shear for cast iron) = 15 MPa. Bearing pressure for rubber bush = 0.8 MPa Material of the pin as same as that of shaft and key MAY 2008 Given data: p =30 kW; n = 900 rpm; Tmax = 1.15 Tmean Solution: P =2 nT/(60*1000) = 2**900*T/60000 T = 318.31 Nm ; Tmax=1.15*318.31 = 366.06 Nm max = 16 Tmax /d ; 40 = 16* 366056/ d d = 40 mm; Design of key: From PSGDB P.NO :5.21, for d= 40 mm; W= 12 mm and h= 8 mm, l= 1.5 d=1.5*ho =60 mm, crushing of key : c = (Tmax/d/2)/(h/2*l) subsitituting the values we get l =91.51 =92 mm Shearing of key : = (Tmax/d/2)/wl Solving this equation we get l = 57.19 =58 mm Taking larger value ,l=92 mm Design of hub: Length of hub: l =92 mm outer dia of hub, D=2d D=2*40=80 mm Torsional sheat stress in hub: h= 16 Tmax/(D(1-K4)) h= 3.88<14 N/mm Design of flange: Thickness of flange =0.5 d = 0.5*40 =20 mm Thickness of protective flange : 0.25 d=10 mm Direct shear stress induced: f = Tmax/D/2/Dtf = 2*366056/ Dtf = 1.82 < 14N/mm,Hence safe. Design of pin: For d= 40 mm, no of pins, N = 4 Nominal dia of pin: db = 0.5d/N =10mm
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5. 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 =0.24. Determine the suitable diameter for a solid shaft, allowing working stress of 60 MPa in tension and 40 MPa in shear for the material of shaft. .Assume that the torque on one pulley is equal to that on the other pulley. Dec 2009 Given data: dA = 600 mm, dB = 400 mm, FA1 = 2250 N, = rad , = 0.24, t = 60 N/mm , =40 N/mm Solution: FA1 / FA2 = e = e0.24 * 2250/ FA2 = 2.125
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FA2 = 1058.6 N Vertical force on pulley A , FA = FA1 + FA2 = 3308.6 N Torque on shaft T T = (FA1 - FA2) dA/2 = (2250 1058.6)300 T = 357.42 * 10 Nmm. Horizontal force on pulley B FB1/FB2 = e = 2.125 FB1 = 2.125 FB2 T = [FB1 - FB2]* dB /2 357.42* 10 = (2.125 FB2 - FB2)200 FB2 = 1588.53 N FB1 = 2.125*1588.53 = 3375.63 N Horizontal force on pulley B FB = FB1+FB2 = 4964.16 N Bending moment on shaft: Considering vertical loading diagram 300 FA 1000
C A BD

RCV RDV Taking moment about point A, - FA * 300 + RDV * 1000 = 0

-

3308.6*300 + RDV * 1000 = 0

RDV = 992.6N RCV + RDV - 3308.6 = 0 RCV = 2316 N Vertical bending moments at point A and B are MAV = RCV * 300 = 2316 * 300 = 694800 N MBV = RDV * 200 = 992.6 * 200 = 198520 N Horizontal loading diagram:
c A B D

Taking moment about point C - FB * 800 + RDH * 1000 = 0

-

4964.16* 800 + RDH * 1000 = 0

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RDH = 3971.33 N RCH + RDH -4964.16 = 0 RCH = 992.83 N Horizontal bending moments at points A and B are: MAH = RCH * 300 = 992.83 * 300 = 297850 N MBH = RDH * 200 = 3971.83 * 200 = 794270 N Resultant bending moments at A and B are: MA = [ MAH + MAV] = [ 694800 + 297850] MA = 756000 N mm MB = [ MBV + MBH ] = [ 198520 + 794270] MB = 818700 N mm Max Bending moment M = MB = 818700 N mm Torque on shaft T = (FA1 FA2)*dA/2 = (2250-1058.6)*300 = 357420 Nmm Equivalent torque Te Te = [(KbM)+ (KtT) Assume Kb =1 , Kt = 1 = [ (1 * 818700) + (1* 357420)] = 893320 Nmm max = 16Te/d 40 = 16*893320/ d d= 48.5 mm d =50 mm.

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UNIT-III Design of temporary and permanent joints TWO MARKS 1. How is a bolt designated? A bolt is designated by a letter M followed by nominal diameter and pitch in mm. It is given as Mdp 2. What factors influence the amount of initial tension? i.External load ,ii.Material used, iii.Bolt diameter 3. What is bolt of uniform strength? A bolt of uniform strength has equal strength at the thread and shank portion. 4. What are the ways to produce bolts of uniform strength? i.Reducing shank diameter equal to root diameter. ii.Drilling axial hole 5. What stresses act on screw fastenings? i.Initial stresses due to screwing up ii.Stresses due to external forces iii.Combined stresses.
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6. What are the different applications of screwed fasteners? The different applications of screwed fasteners are a.For readily connecting & disconnecting machine parts without damage b.The parts can be rigidly connected c.Used for transmitting power 7. What are the advantages of screwed fasteners? The advantages of screwed fasteners are a. They are highly reliable in operation b.They are convenient to assemble & disassemble c.A wide range of screws can be used for various operating conditions d.They are relatively cheap to produce.

8. Define pitch. Pitch is defined as the distance from appoint on one thread to the corresponding on the adjacent thread in the same axis plane.

9. Define lead. Lead is defined as the distance, which a screw thread advances axially in one rotation of the nut. 10. What are the different types of metric thread? 1. BSW (British standard Whit worth) 2. BSE (British standard End 11. Define welding. Welding can be defined as a process of joining two similar or dissimilar metals with or without application of pressure along with or without addition of filler material.
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12. What are the types of welded joints? i.Butt joint ii.Lap joint iii.T joint iv.Corner joint v.Edge joint. 13.What are the two types of stresses are induced in eccentric loading of loaded joint? 1. Direct shear stress. 2. Bending or torsional shear stress. 14 Define butt and lap joint Butt joint: The joint is made by welding the ends or edges of two plates. Lap joint: The two plates are overlapping each other for a certain distance. Then welded. Such welding is called fillet weld. 15 When will the edge preparation need? If the two plates to be welded have more than 6mm thickness, the edge preparation should be carried out. 16. What are the two types of fillet weld? i.Longitudinal or parallel fillet weld ii.Transverse fillet weld 17. State the two types of eccentric welded connections. i.Welded connections subjected to moment in a plane of the weld. ii.Welded connections subjected to moment in a plane normal to the plane of the weld. 18. What are the practical applications of welded joints? It has employed in manufacturing of machine frames, automobile bodies, aircraft, and structural works. 19.State any two advantages of welded joints over rivet joints April 08,09 1. Light in weight, 2. Low number of labour.
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3.Leak proof 20. What is the meaning of bolt M242 M242 represents nominal diameter of bolt is 24 mm and the pitch is 2mm. 21.Name the possible modes of failure of riveted joints Tearing at weakened section and shearing and crushing of the rivets. What is threaded joint? Threaded joint is defined as the seperable joint of two or more machine parts held together by means of threaded fastenings such as bolt, nut etc.. 22. What is a stud? Stud is a bolt in which the head is replaced by athreaded end. It passes through one of the parts to be connected and is screwed to the other part.

23.What is the minimum size for fillet weld? If the required weld size from strength consideration is too small how will you fulfil the condition of minimum weld size. Nov 08 It is defined as the minimum size of the weld for a given thicknees of the thinner part joined or plate to avoid cold cracking by escaping the rapid cooling. Size of the weld, h = 2 throat thickness. 16 MARKS 1.A plate 75 mm wide and 12.5 mm thick is joined with another plate by a single transverse weld and a double parallel fillet weld as shown in Fig. 1. The maximum tensile and shear stresses are 70 MPa and 56 MPa respectively. Find the length of each parallel
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fillet weld, if the joint is subjected to both static and fatigue loading. Stress concentration factor for transverse weld is 1.5 and for parallel fillet weld is 2.7 May 08 Given data: b = 75 mm; h = 12.5 mm; t = 70 N/mm = 56 N/mm, kft = 1.5; Kfb = 2.7 Solution: Load carrying capacity: P = t bh =70*75*12.5 = 65625 N Joint subjected to static loading P1 = bt=bh/2 = 56*75*12.5/2 = 37123.1 N The load carried by double parallel welds is P 2 P2 = (l+l)t = 2lh/2 = 989.95 l N The total load P= P1+ P2; 65624 = 37123.1 + 989.95 l; l= 28.8 mm\ Joint subjected to subjective loading: The load carried by asingle transverse load is P1=bt/Ka = bt/kft 2 = 24748.74 N The load carried by double parallel welds P2 = /Kfb (l+l)t = 366.65 N Total load P = P1+ P2; l = 111.5 mm 2. A welded joint as shown in Fig. 2 is subjected to an eccentric load of 2 kN. Find the size of weld, if the maximum shear stress in the weld is 25 MPa. May 08 Given data : P = 2000 N; = 25 N/mm; e= 120 mm, l = 40mm Solution: I.Moment of inertia for weld group about horizontal axis through C.G: Ixx = 2[1/12 lt] = 1/6*40 t = 10666.67 t mm4 II.direct shear stress d: A = A1+A2 lt+ lt= 2lt= 2*40*t = 80t d =P/A = 2000/80t 25/t, Moment induced shear stress b
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M = Pe = 2000*120=240000 Nmm, y= l/2= 20 mm The max moment induced shear stress d = M.Y/Ixx = 450/t N/mm Resultant shear stress: = ( d + b) = 450.69/t N/mm Weld size (h)= 25 = 450.69/t,t = 18.028 mm h= 2 t= 25.49 =26 mm t = h/2= 18.38 mm 3.Design a knuckle joint to with stand a tensile load of 70 KN using steel with the following permissible stresses (in tension) = 60 MPa (in crushing) = 72 MPa (in shear) = 48 MPa. May 08 Given data Load p = 70000 N, (in tension) = 60 MPa (in crushing) = 72 MPa ,(in shear) = 48 MPa Solution : `Diameter of rod,d t = P/(2(.d/4)=38.54 =40 mm Diametr of knuckle pin (dp): = P/(2( dp)/4), dp = 30.46 = 31 mm. Thickness of single eye(t): The crushing stress ,c = P/( dp*t) 72 = 70000/31t t1 = 31.36 =32 mm also, t1 = 1.25 d = 1.25 40 = 50mm. Thickness of fork (tf): The crushing stress induced in fork, c = P/(231 tf) tf = 13.68 =16 mm. the minimum thickness of the fork = 0.75 d = 0.75(40)=30 mm Outer diameter of eye (D): Tensile stress induced in asingle eye, t= P/(D- d p)t 60 = 70000/(D-31)50:D =54.33; D =55 mm shear stress induced in a single eye = P/(D- d p)t
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48 = 70000/(D-31)50;D =60.26 =61 mm. failure of fork in tension: , t = P/(D- dp) t1 t = 70000//2(61-31)30= 38.89 < 60 N/mm hence fork end is safe in tension failure of fork end in tension = P/2(D- dp) t1 = 70000/2(61-31)30 = 38.89 < 48 N/mm hence fork end is safe in shear

UNIT-IV Design of energy storing elements TWO MARKS 1. What is a spring? A spring is an elastic member, which deflects, or distorts under the action of load and regains its original shape after the load is removed. 2. State any two functions of springs. i. To measure forces in spring balance, meters and engine indicators. ii.To store energy. 3. What are the various types of springs? i.Helical springs ii.Spiral springs
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iii.Leaf springs iv.Disc spring or Belleville springs 4. Classify the helical springs. a.Close coiled or tension helical spring. b.Open coiled or compression helical spring. 5. Define Leaf springs A leaf spring consists of flat bars of varying lengths clamped together and supported at both ends, thus acting as a simply supported beam. 6. Define Belleville Springs They are made in the form of a cone disc to carry a high compressive force. In order to improve their load carrying capacity, they may be stacked up together. The major stresses are tensile and compressive. 7. What is spring index (C)? The ratio of mean or pitch diameter to the diameter of wire for the spring is called the spring index. 8. What is pitch? The axial distance between adjacent coils in uncompressed state.

9. What is solid length? The length of a spring under the maximum compression is called its solid length. It is the product of total number of coils and the diameter of wire. Ls = n x d Where, nt = total number of coils. 10. What are the requirements of spring while designing? a.Spring must carry the service load without the stress exceeding the safe value. b.The spring rate must be satisfactory for the given application. 11. What are the end conditions of spring?
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a.Plain end. b.Plain and ground end c.Squared end d.Squared and ground end. 12. What is buckling of springs? The helical compression spring behaves like a column and buckles at a comparative small load when the length of the spring is more than 4 times the mean coil diameter. 13. What is surge in springs? The material is subjected to higher stresses, which may cause early fatigue failure. This effect is called as spring surge. 14. What is a laminated leaf spring? In order to increase, the load carrying capacity, number of flat plates are placed and below the other. 15. What semi elliptical leaf springs? The spring consists of number of leaves, which are held together by U- clips. The long leaf fastened to the supported is called master leaf. Remaining leaves are called as graduated leaves.

16. What is nipping of laminated leaf spring? Prestressing of leaf springs is obtained by a difference of radii of curvature known as nipping. 17. What are the various application of springs? The springs are used in various applications, they are a.Used to absorb energy or shocks (e.g. shock absorbers, buffers, e.t.c.) b.To apply forces as in brakes clutches, spring-loaded valves, e.t.c. c.To measure forces as in spring balances and engine indicators
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d.To store energy as in watches 18 Define free length.Apl 2011 Free length of the spring is the length of the spring when it is free or unloaded condition. It is equal to the solid length plus the maximum deflection or compression plus clash allowance. L f= solid length + Ymax + 0.15 Ymax 19. Define spring index. Spring index (C) is defined as the ratio of the mean diameter of the coil to the diameter of the wire. C =D/d 20. Define spring rate (stiffness). The spring stiffness or spring constant is defined as the load required per unit deflection of the spring. K= W/y , Where W-load ; y-deflection 21. Define pitch. Pitch of the spring is defined as the axial distance between the adjacent coils in uncompressed state. Mathematically Pitch=free length n-1 22. What are the points to be taken into consideration while selecting the pitch of the spring? The points taken into consideration of selecting the pitch of the springs are a.The pitch of the coil should be such that if the spring is accidentally compressed the stress does not increase the yield point stress in torsion. b.The spring should not be close up before the maximum service load is reached. 23. Define active turns. Active turns of the spring are defined as the number of turns, which impart spring action while loaded. As load increases the no of active coils decreases. 24. Define inactive turns.
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Inactive turns of the spring is defined as the number of turns which does not contribute to the spring action while loaded. As load increases number of inactive coils increases from 0.5 to 1 turn. 25. What are the different kinds of end connections for compression helical springs? Nov 09 The different kinds of end connection for compression helical springs are a.Plain ends b.Ground ends c.Squared ends d.Ground & square ends 26. Write about the eccentric loading of springs? If the load acting on the spring does not coincide with the axis of the spring, then spring is said to be have eccentric load. In eccentric loading the safe load of the spring decreases and the stiffness of the spring is also affected.

27. Explain about surge in springs? When one end of the spring is resting on a rigid support and the other end is loaded suddenly, all the coils of spring does not deflect equally, because some time is required for the propagation of stress along the wire. Thus a wave of compression propagates to the fixed end from where it is reflected back to the deflected end this wave passes through the spring indefinitely. If the time interval between the load application and that of the wave to propagate are equal, then resonance will occur. This will result in very high stresses and cause failure. This phenomenon is called surge 28. What are the methods used for eliminating surge in springs? The methods used for eliminating surge are
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a.By using dampers on the center coil so that the wave propagation dies out b.By using springs having high natural frequency. 29. What are the disadvantages of using helical spring of non-circular wires? a.The quality of the spring is not good b.The shape of the wire does not remain constant while forming the helix. It reduces the energy absorbing capacity of the spring. c.The stress distribution is not favorable as in circular wires. But this effect is negligible where loading is of static nature. 30. Why concentric springs are used? a.To get greater spring force within a given space b.To insure the operation of a mechanism in the event of failure of one of the spring 31. What is the advantage of leaf spring over helical spring? The advantage of leaf spring over helical spring is that the end of the spring may be guided along a definite path as it deflects to act a structural member in addition to energy absorbing device. 32. Write notes on the master leaf & graduated leaf? The longest leaf of the spring is known as main leaf or master leaf has its ends in the form of an eye through which bolts are passed to secure the spring. The leaf of the spring other than master leaf is called the graduated leaves. 33. What is meant by nip in leaf springs? By giving greater radius of curvature to the full length leaves than the graduated leaves, before the leaves are assembled to form a spring thus a gap or c 34. What is the application of leaf spring?

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The leaf springs are used in automobiles as shock absorbers for giving suspension to the automobile and it gives support to the structure. 35. Define flat spiral spring. A flat spiral spring is a long thin strip of elastic material wound like a spiral. These springs are frequently used in watch springs, gramophones, e.t.c 36. What are the differences between helical torsion spring and tension helical springs? Helical torsion springs are wound similar to that of tension springs but the ends are shaped to transmit torque. The primary stress in helical torsion spring is bending stress whereas in tension springs the stresses are torsional shear stresses. 37. Define helical springs. The helical springs are made up of a wire coiled in the form of a helix and is primarily intended for compressive or tensile load. 38. What are the different types of helical springs? The different types of helical springs are a.Open coil helical spring b Closed coil helical spring 39.State difference between Closed coil helical springand Open coil helical spring Closed coil helical spring:The spring wires are coiled very closely, each turn is nearly at right angles to the axis of helix Helix angle is less than 10 Open coil helical spring The wires are coiled such that there is a gap between the two consecutive turns. Helix angle is large (>10) 40. What is flywheel? Flywheel is a machine elements used to minimize the fluctuation of speed in a engine.
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41. What is the function of flywheel? Apl 08 A flywheel used in machine serves as a reservoir which stores energy during the period when the supply of energy is more than the requirement and releases it dulling the period when the requirement of energy is more than the supply. 42. Define the term fluctuation of speed and fluctuation of energy.Nov 08,Nov 09 The ratio of maximum fluctuation of speed to the mean speed is called co efficient of fluctuation of speed. The ratio of fluctuation of energy to the mean energy is called coefficient of fluctuation of energy. 43. State the type of stresses induced in a rim flywheel? 1.Tensile stress due to centrifugal force 2.Tensile bending stress caused by the restraint of the arms and 3.The shrinkage stresses due to unequal rate of cooling of casting. 44.What are the stresses induced in flywheel arms? 1.Tensile stress due to centrifugal force. 2.Bending stress due to torque 3.Stress due to belt tension. 45. How does the function of flywheel differ from that of governor? A governor regulates the mean speed of an engine when there are variations in the mean loads. It automatically controls the supply of working fluid to engine with the varying load condition & keeps the mean speed with contain limits. It does not control the speed variation caused by the varying load. A flywheel does not maintain const speed. 46.State any two applications of leaf springsNov 08 1.structural members,2Energy absorbing devices 47.What are the applications of concentric springs
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May 2010 Valve springs in heavy duty diesel engines, rail road suspensions etc.. 48.Two springs of stiffness K1, K2 are connected in series what is the stiffness of connection?May 2010 Two springs of stiffness K1, K2 are connected in series Then combined stiffness, 1/K =1/ K1 + 1/ K2 16 MARKS 1.Design a close-coiled helical spring of siliconmanganese steel for the valve of and IC engine capable of exerting a net force of 65N when the valve is open and 54N when the valve is closed. The internal and external diameters are governed by space limitations, as it has to fit over bushing of 19mm outside diameter and go inside a space of 38mm diameter. The valve lift is 6mm. Given data: P min = 54N P max = 65N D min = 19mm D max = 38mm Y o = 6mm Solution: Since material is not specified, let us take 20Mn2 alloy steel which is commonly used for spring. From PSGDB page 1.13,
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 y = 44kg/mm = 44*9.81 = 432N/mm Assuming, yield shear stress, y = 0.5 y We have y = max = 0.5*432 = 216N/mm We can also assume that D = D min+ D max/2 = 19+38/2 = 28.5mm Let us assume that d= 5mm C = D/d = 28.5/5 = 5.7 K s = 4c-1/4c-4+0.615/c = 4(5.7)-1/4(5.7)-4 + 0.615/5.7 = 1.26 Let us find the shear stress developed in the spring for the assumed value of d =5mm We know that = k s*8*p max C/d =1.26*8*65*5.7/*5 = 47.83N/mm since < max, design is safe. We know that Y = 8pcn/Gd Assuming, G = 84*10N/mm, n= 26.1 say 27. 2. Design and draw suitable flywheel for a four stroke four cylinder 133kW engine running at 375rpm. Due to space restriction the flywheel diameter should not exceed 1.2m. Given data: Power = 133kW = 133 *10w
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Speed, N = 375 rpm Maximum diameter of the rim, D = 1.2m Solution: Since it is given that the flywheel diameter should not exceed 1.2m, let us assume that the mean diameter of the flywheel rim as 1.1 m. R = 0.55m. Also, assume Maximum fluctuation of energy, E =20% of energy developed per revolution (E) and Speed variation is 1% either way from mean. Therefore, the total fluctuation of speed, N1 N2 = 2% of mean speed = 0.02N Mass of the flywheel rim: Let m = mass of the flywheel rim in kg Work done (or) energy developed per revolution. E = p*60/N = 133*10*60/375 = 21280N-m Maximum fluctuation of energy, E =0.2E = 0.2*21280 = 4256N-m Since the speed variation is 1% either way from mean, therefore the total fluctuation of speed, N1- N2 = 2% of mean speed = 0.02N and co-efficient of fluctuation of speed, K s = n1-n2/n1 = 0.02 Velocity of the flywheel, V = DN/60 = *1.1*375/60 = 21.598m/sec
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We know that the maximum fluctuation of energy (E) 4256 = mV Ks =m (21.598) 0.02 m = 21.598*0.02/4256 = 456.17kg ans. Cross-sectional dimensions of the flywheel rim : Let us assume, h = depth (or) thickness of the rim in meters and b = width of the rim in meters, 2h Cross-sectional are of rim, A = b *h = 2h*h = 2h We know that mass of the flywheel rim (m), M = AD*p (assume, = 7200kg/m) 456.17 = A*D* = 2h**1.1*7200 h = 0.0957m = 95.7mm b = 2h = 2*95.7 =191.4mm Diameter and length of hub: Let us assume, d = diameter of the hub d 1= diameter of the shaft and l = length of hub We know that mean torque transmitted [(Mt) max] by the shaft is twice the mean torque. (mt)max =2*(mt)mean = 2*3386.8 (mt)max = 6773.6N-m = 6.773*106 N-mm We also know that maximum torque transmitted by the shaft
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ans. ans.

6.773*106 = /16**d1 =/16*40*d1 d 1= 95.2mm

(assume , = 40N/mm)

ans.

The diameter of the hub (d) is made equal to twice the diameter of the shaft (d1) and length of hub (l) is equal to the width of rim (b). D =2d1 =2*95.2 = 190.4mm And l=b = 190.4mm ans. ans.

Cross-sectional dimensions of the elliptical arms: Let, a = major axis C = minor axis Assume minor axis = 0.5 * major axis C = 0.5a N = number of arms (assume, n=6)

b = bending stresses for the material of the arms (assume b = 14Mpa) b =14N/mm We know that the maximum bending moment in the arm at the hub end, which is assumed as cantilever, is given by M = (Mt)/D.n (D-d) = 3386.8*10/1.1*6(1.1-0.1904) = 466.76*10N-mm And section modulus for the cross-section of arm, Z = /32 ca = /32 (0.5a)a = 0.05a We know that the bending stress (b),
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14 =M/Z 14 = 466.76*10/0.05a a = 87.36mm Say, major axis, a = 88mm c= 0.5a c= 0.5*88 = 44mm ans. ans.

A punching press pierces 30 holes per minute in a plate using 12 kN-m of energy per hole during each revolution. Each piercing takes 35% of the time needed to make one revolution. The punch receives power through a gear reduction unit which in turn is fed by a motor driven belt pulley 750 mm diameter and turning at 240 rpm. Find the power of the electric motor if overall efficiency of the transmission unit is 80%. Design a cast iron flywheel to be used with the punching machine for a coefficient of fluctuation of speed is 0.05, if the space considerations limits the maximum diameter to 1.3 m. Allowable shear stress in the shaft mateial = 48 MPa Allowable tensile stress for cast iron = 5 MPa Density of cast iron = 7200 Kg/m Given data: np = 30 rpm, E = 12 10 J, n = 240 rpm, = 0.8 ,Cs = 0.05 , Dmax = 1.3 m, all = 5 N/mm, = 7200 kg/m , = 48 N/mm Solution: The punching operation takes place during 35% of rotation of the punching machine crank shaft ( = 126). Hence during 65% of the rotation of the crank shaft ( =234), the energy is stored in the flywheel wheel. Therefore, the max fluctuation of energy is E = 0.65E = 0.65 12000=7800 J. Assumptions : 1. the flywheel used is a rim type flywheel with C= 0.9
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2. the width of flywheel rim is taken as twice its thickness 3. the no of flywheel arms is N= 6. 4. For flywheel arms , the elliptical cross section is a1 =2b1 5. The max torque is taken as twice the mean torque. Dimensions of flywheel rim : Mean angular speed = 2n/ 60 = 2*240/60 = 25.13 rad/s. The max diameter of the flywheel is 1.3 m. let take mean diameter as Dm = 1.1 m Rm =0.55 m , E = ICs,I = 247.02 kg m, For a flywheel rim, Ir = CI =0.9*247.02=222.32 kgm Ir = mr Rm = (2 Rm bt) 222.32 = 2 * 0.55 * 2t *t *7200 t = 121.5 mm =122 mm Stresses in flywheel rim: V =Rm = 0.55* 25.13 = 13.82 m/s. The resultant stress induced in flywheel rim is rim = V = [ 0.75 +(0.5Rm/Nt)] = 7200*13.82*[0.75 + 0.5*0.55/(6*0.122)] = 1.88 *106 N/mm < 5 N/mm rim < all Hence the flywheel rim is safe. Diameter of flywheel shaft: The average torque on punching machine shaft Tavp = E/2 = 12000/2 Tavp = 1909.86 Nm The reduction ratio from flywheel shaft to punching machine shaft, G = 240/30 = 8 The avg torque on flywheel shaft Tavg = Tavp / G = 1909.86/8 = 238.73 Nm The maximum torque on flywheel shaft, Tmax = 2 Tavg = 2*238.73=477.465 Nm =16 Tmax / d , 48 = 16*477465/ d d = 37 mm = 40 mm radius of hub, rb = d= 40 mm
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From PSGDB P.No 5.21, for d = 40 mm Width of key w = 12 mm Height of key,h= 8 mm Considering shearing of key: d = 2Tmax/dwl , 48 = 2*477465/(40*12*l) l = 41.44 =42 mm Considering crushing of key c = 4Tmax / dhl , 96 = 4*477465/(40*8*l) l = 63 mm Key dimensions W = 12 mm, h = 8 mm, l = 63 mm Dimensions of flywheel arms The resultant stress induced in the flywheel arm is arm = V + Ta (Rm - rb)/(NRmZa) = * 7200*13.82 + (477465*(0.55-0.04))/ (6*0.55*Za) = 1.031 *106 + 73.8 / Za For the safety of flywheel arms arm = all 1.031 *106 + 73.8 / Za = 5 * 106 73.8/ Za = 3.988 * 106 Za = 1.86 *10-5 m .eqn 3 For elliptical cross section of the arm at the hub end, Za = /32*a12*b1 = /32(2 b1)b1 = /8 b1 ..eqn 4 From eqn 3 and 4, /8 b1 =1.86 *10-5 b1= 0.03617 m = 36.17 mm = 37mm Power requirement of electric motor Power input to the punching machine PP = energy input to the punching machine per stroke* No of punching strokes per second =E*nP/60= 12000*30/60 = 6000 W Power requirement of electric motor,P P = PP/ m = 6/0.8 = 7.5 kW Flywheel dimensions: Flywheel rim Rm = 550 mm,
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t = 122 mm, b =244 mm flywheel arms : N =6 a1 =74 mm, b1 =37 mm flywheel hub: db = 2 rb =80mm lb =63 mm Shaft : d = 125 mm, Key : w = 12 mm, h = 8 mm,l= 63 mm.

UNIT - V Design of Bearings and miscellaneous elements TWO MARKS 1. What is bearing? Bearing is a stationery machine element which supports a rotating shafts or axles and confines its motion. 2. Classify the types of bearings.
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(i). Depending upon the type of load coming upon the shaft: a. Radial bearing, b.Thrust bearings. (ii).Depending upon the nature of contact: a.Sliding contact, b.Rolling contact bearings or Antifriction bearings. 3.What are the required properties of bearing materials? Bearing material should have the following properties, i.High compressive strength, ii.Low coefficient of friction, iii.High thermal conductivity, iv.High resistance to corrosion, v.Sufficient fatigue strength, vi.It should be soft with a low modulus of elasticity and vii. Bearing materials should not get weld easily to the journal material. 4. What is a journal bearing? A journal bearing is a sliding contact bearing which gives lateral support to the rotating shaft. 5. What are the types of journal bearings depending upon the nature of contact? i.Full journal bearing, ii. Partial bearing and iii. Fitted bearing. 6. What are the types of journal bearing depending upon the nature of lubrication? i.Thick film type, ii.Thin film type iii.Hydrostatic bearings, iv.Hydrodynamic bearing. 7. What is known as self acting bearing? Nov 07 The pressure is created within the system due to rotation of the shaft, this type of bearing is known as self acting bearing. 8.What is the advantage of Teflon which is used for bearing?May 2008 1.It has low coefficient of friction,
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2.It can be used at higher temperature 3.Chemically inert. 9.What is meant by life of antifriction bearing?Nov 08 It is defined as the life of 90% of group of identical bearing will complete or exceed before fatigue failure. 10.What is a Quill bearing? Apl 2010 Quill bearings are characterized by cylindrical rollers of very small diameter and relatively long.they are also called as needle bearings. 11.For ajournal bearing, the maximum operating temperature must be less than 80C why? Nov 2010 Temperature rise will result in the reduction of the viscosity of the oil used in the bearing.This would lead to metal to metal contact, thereby affecting the bearing performance and life. 12.Why is a piston end of a connecting rod kept smaller than the crank pin end Nov 2010 The piston end of the connecting rod experiences the less bending moment than the crank end. Hence on the basis of uniform strength, the piston end of the connecting rod is smaller. 13.List any foyr advantages of the rolling bearing over sliding bearings Apl 09 1.Starting friction is low, 2.Lubrication is simple, 3.It reqires less axial spaceand more diametral force 4.Heavier loads , higher speeds are permissible. 14.State the disadvantages of the thrust ball bearing Nov 09 High initial cost,less capacity to withstand shock,noisy operation at high speed,life is infinite, Design of bearing housing is complicated.

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15. What are the stresses setup in an IC engine connecting rod? 1. Tensile stresses, 2.compressive stresses, 3. Bending stresses due to inertia forces

16. What is the method of manufacturing connecting rod? Forging is the method of manufacturing the connecting rod. 16 MARKS 1.A single row deep groove ball bearing no.6002 is subjected to an axial thrust load of 1000N and a radial load of 2200N. Find the expected life that 50% of the bearings will complete under this condition.Nov 2010 Solution: From PSGDB 4.14, for bearing no. 6002 Co = 2850kgf = 28500N C = 5590kgf = 55900N Fa/co = 1000/28500 = 0.035 From table 5.1.2 or PSGDB 4.4, corresponding to Fa /co = 0.035, the value of e = 0.235 (by interpolation). Since fa/fr =1000/2200 = 0.454>e, from table 5.1.2 or PSGDB 4.4., the radial load factor x = 0.56 and thrust load factor y = 1.83 (by interpolation). The service factor is selected from table 5.1.3 or PSGDB 4.2 considering rotary machine with no impact condition.

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S = 1.1 to 1.5 say 1.3 Equivalent load, p = (xfr + y fa) s =(0.56*1.83*1000)1.3 P = 39806N We know that the rating life of the bearing L = (C/P)a = (55900/39806) = 2.77 million revolutions. Expected life at 50% reliability : L50 /L 90 = [ln (1/R50)/ln(1/R90)]1/3 L50
=

ln (1/0.5)/ (ln1/R90)1/1.17 * 2.77*5

L50 = 13.85 million revolutions 2.A bearing for an axial flow compressor is to carry a radial load of 2500 N and thrust of 1500 N. The service imposes light shock and the bearing will be in use for 40 hours/week for 5 years. The speed of the shaft is 1000 rpm. Select suitable ball bearing for the purpose and give the required tolerances on the shaft and the housing. Diameter of the shaft is 50 mm. May 08 Given data: Radial load, Fr =2500 N; axial load, Fa =1500 N Lh10 = 40*52*5 =10400 hrs, n= 1000 rpm d=50 mm Solution: Rating life and service factor: L10=Lh10*60*n/106 =624 million revolutions, For light shock, Ka = 1.5 from PSGDB P.No 4.2 From PSGDB P.no 4.12, For d = 50 mm Select bearing no 6010 with C= 1700 kgf =16677 N,Co = 1370kgf =13439 N And Fa/Co = 0.11 From PsgDB p.no 4.4 , For Fa/Co = 0.11, e = 0.297 (by linear interpolation)
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Fa/Fr = 1500/2500 =0.6 On comparing Fa/Fr > e Take X= 0.56 and Y = 1.47 (by linear interpolation) Equivalent dynamic load Pe = (X v Fr + YFa)Ka = (0.56*1*2500 +1.47*1500)1.5 = 5407.5 N Required dynamic capacity Cr =
Cr = 46208.8N >16677 N So. it is unsafe,Select

(L10)1/3

Pe

higher bearing from PSGDB P.no 4.15 for d = 50 mmC = 7000 kgf = 68670 N Co = 5300kgf =51993N Fa/Co = 0.029 From PSGDB P.No 4.4 for Fa/Co=0.029 e=0.225 , Fa/Fr = 1500/2500 =0.6, Fa/Fr >e Take X= 0.56, Y = 1.946 by linear interpolation Equivalent dynamic load Pe = (X v Fr + YFa)Ka = (0.56*1*2500+1.946*1500)1.5 = 6478.5 N Required dynamic capacity Cr = (L10)1/3 Cr = ss360.83 < 68670 N Hence it is safe. Tolerance on shaft : From PSGDB P.No for d =50 mm, service condition of light shock with rotating inner race , the tolerance on the shaft is 50 j6 ie 50 (+0.011/-0.005 ) mm. from PSGDB P.NO 3.8 Tolerance on housing: From PSGDB P.NO 4.15 for bearing no 6410, the outer diameter of bearing or inner diameter on housing is 130 mm. From PSGDB P.NO 4.9 for service condition of light shock and stationary outer race, the tolerance on housing is 130J7 ie 130 (+0.026/-0.014) from PSGDB P.NO 3.9 3..The journal bearing supports a load of 150 kN due to turbine shaft of 300 mm diameter running ar 1800 rpm. The bearing clearance is 0.25 mm, while the
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Pe

allowable bearing pressure is 1.6 N/mm.if the viscosity of lubriacating oil at bearing temperature of 60C is 0.02 kg/ms.determine (i)the length of bearing and (ii) the amount of heat to be removed by the lubricant per minute. May 2009 Given data: Load W = 150kN, d =300 mm, speed , n =1800 rpm , bearing clearance 2C = 0.25 mm, p = 1.6 N/mm , Z = 0.02 kg/m-s Ta = 60C Solution: 1.length of bearing,(l): p= W/(ld), l= W/pd = 150000/(1.6*300)=312.5 mm 2.Dynamic viscosity ,Z= 0.02 kg/m-s = 20*10-9 N-s/m 3. Radial clearance(C) and journal radius (r), 2c = 0.25 mm c = 0.125 mm, r =d/2 = 300/2 =150 mm. 4.Coefficient of friction , = 19.5 (r/c)(Zn/p)+ K , where K = 0.002 for 0.75<l/d<2.8, = 19.5(150/0.125)(20*10-930)/1.6 + 0.002 = 0.010775. 5.Power lost in friction(Pf) Pf = (2*n)( Wr/106) = 2*30*0.010775*150000*150/106 = 45.7 kW

6.Heat to be removed by the lubricant per minute: Heat generated = Heat dissipated Hg =Hd = Pf
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= 45.7 kJ/s = 45.7*60 kJ/min, Hd = 2742 kJ/min

4..A full journal bearing of 50 mm diameter and 100 mm length has a bearing pressure of 1.4 N/mm.The speed of the journal is 900 rpm and the ratio of journal diameter to the diameteral clearance is 1000. The lubricating oil used has absolute viscosity at operating temperature of 75 is 0.011 kg / m-s. The room temperature is 35.Determine the amount of artificial cooling required and the mass of lubricating oil required if the difference between the outlet and inlet temperature of the oil is 10.Take specific heat capacity of oil as 1850 J/kg/C Dec 2008 Given Data: d=50mm, l=100 mm, p=1.4N/mm, n=900 rpm, r/c =1000 To = 75C, Ta = 35 C T =10C, Cp = 1850J/kgC,Z = 0.011 kg/ m-s Solution: Load of bearing p=W/ld, W = 1.4*50*100 = 7000 N (l/d) ratio: (l/d) = 100/50 = 2 Sommerfield number (S): S = Zn/p(r/c) = 1000 * (11*10-9 * 15)/1.4 = 0.118
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From PSGDB P.No 7.36: For l/d = 2, S =0.118 lies between 0.026 and 0.0123 . it can be found by linear interpolation (r/c) = 2.483 = 2.483/1000=2.483*10-3 Power lost in friction : Pf Pf = (2*n)( Wr)/106 = 2*15*2.483 *10-3 * 7000*25/106 = 0.040953 kW Heat generation Hg = Pf Hg = 0.040953 kW Heat dissipation Hd Hd = 4.75*10*100*10-3*50*10-3/(1+1)*(75-35)*10-3 = 4.75*10-3 kJ/s Amount of artificial cooling required (Q): Q =Hg Hd = 0.040593-0.00475 = 0.0362 kJ/s 36.2 J/s Mass of lubricating oil : Hg = m.Cp.t , m= Hg/Cp. t m= 2.214*10-3 kg/s = 0.133 kg/min 5.A ball bearing operates on awork cycle consisting of three parts: a radial load of 3000 N at 1440 rpm for one quarter of cycle , aradial load of 5000 N at 720rpm for half of the cycle and a radial load of 2000N at 1440 rpm for the remaining part of the cycle.If expected rating life of the bearing is 10000 hrs, calculate the basic dynamic capacity of the bearing Dec 09 Given data: Pr1 = 3000 N, n1= 1440 rpm, fraction of cycle = 0.25 Pr2 = 5000 N, n2 = 720 rpm, fraction of cycle = 0.5 Pr3 = 2000N, n3 = 1440 rpm, fraction of cycle = 0.25 , Lh10 = 10000 hrs Solution: Equivalent load :Pe N1 = 0.25*Lh10*60*n1/106
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= 0.25*10000*60*1440/106 =216 million revolutions N2 = 0.5* Lh10*60* n2/ 106 = 0.5*10000*60*720/106 = 216 million revolutions. N3 = 0.25 *Lh10*60* n3/106 = 0.25 * 10000*60*1440/106 = 216 million revolutions Pe = [N1 (Pe1) + N2 (pe2) + N3 (pe3)/(N1+N2+N3) ]
1/3

= 3823.01 N. Basic dynamic capacity : L10 = N1+N2+N3 = 216+216+216 = 648 million revolutions L10= (C/ Pe) , (C/ Pe ) = (L10) 1/3 C = 6481/3 * Pe C = 33082.4 N

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