Mech-V-Design of Machine Elements I (10me52) - Solution

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)
Solution:
i) FG350:- Grey Cast Iron with an ultimate tensile strength of 350 N/mm2.
ii) FeE300; - Steel with gold strength of 350 N/mm2.
iii) C35Mn75:- Steel with 0.35% carbon & 7.5% Manganese.
iv) X20Cr18Ni2:- Steel with 0.65% Manganese.
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 = 45
ii) Principal stresses 1, and 2 and their directions.
iii) Maximum shear stress and its plane.
(June/July 2014)
Solution:
Department of Mechanical Engineering, SJBIT, Bengaluru.
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3. Draw stress - strain diagram for mild steel subjected to tension. Explain the significance
of salient points.
(Dec/Jan 2015)
Solution: A typical tensile test curve for the mild steel has been shown below,
Salient Points of the Graph:
(A) It is evident from the graph that the strain is proportional to strain or elongation is
proportional to the load giving a straight line relationship, This law of proportionality is
valid upto a point A, or we can say that point A is some ultimate point when the linear
nature. of the graph ceases or there is a deviation from the linear nature, This point is
known as the limit of proportionality or the proportionality limit .
(B) For a short period beyond the point A, the material may still be elastic in the sense that the
deformations are completely recovered when the load is removed. The limiting point B is
termed as Elastic Limit.
(C) and (D) - Beyond the elastic limit plastic deformation occurs and strains are not
totally recoverable. There will be thus permanent deformation or permanent set when load is
removed, these two points are termed as upper and lower yield points respectively, the stress at
the yield Point is called the yield strength.
4. What are the basic requirements of machine elements? Explain briefly. (June/July 2015)
Solution:
The preliminary requirement of machine elements may be
1. Availability of the raw materials.
2. Suitable for the materials for the working condition at its application.
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3. The cost of the material.

4. Physical properties of the materials such as elasticity, creep, fatigue etc.
5. Chemical composition retention property.
6. Easy manufacturing.
5. What are the factors to be considered for selection of material for a machine component?
(June/July 2015)
Solution:
Selection of material for a machine component can be considered based on strength,
stiffness, rigidity, ductility, toughness, resistance, fatigue resistance, ductile as brittle transition,
creep resistance, wear resistance, oxidation and corrosion resistance. Ductile to brittle transition,
creep resistance, friction characteristics, hardenability, castability, formability, weldability,
machinability and specific weight.
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)
Solution:
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7. For the stress-element shown in Figure, find the principal stresses and directions.
(June/July 2016)
Solution:
8. Write a note on uniform strength
(Jun/July2016)
Solution:
In many applications such as connecting rods, mechanical presses and power hammers,
bolts are subjected to shock or impact loads. In such cases, bolts are designed to absorb
maximum impact energy and also to resist rupture.
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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)
Solution:
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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)
Solution:
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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)
Solution:
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)
Solution:
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5. In a plate of C45 steel (y = 353 MPa) subjected to a system of loads, following stresses are
induced at critical point: x =150 N/mm2, y = 100 N/mm2 a nd 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)
Solution:
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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)
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Solution:
Safe load P = 20.70 KN

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 instantaneous extension
is 2 mm, what is the corresponding stress and the value of unknown weight? Take E = 200
GPa.
(June/July 2016)
Solution:
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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)
Solution:
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UNIT 3
DESIGN FOR FATIGUE STRENGTH
1. Derive Goodman's equation.
(June/July 2014)
Solution:
Page 15

2. Explain cumulative fatigue damage.
10ME52
(Dec 2014)
Solution:
When more than one stress level exists in the working cycle, the load cycle should be
divided into number of intervals in each of which the mean and alternating stress can be
considered as constant. The equivalent completely reversed stress should be calculated for each
position. Let N1 be the number of stress cycles before fatigue failure, if only 1 is acting. One
stress cycle will take 1/N1 of the fatigue life and as there are n1 cycles at the stress level, the
proportional damage is n 1/N1 similarly the proportional damage for stress level 2 will be n2/N2
and so on.
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)
Solution:
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4. A Cantilever beam made of 35C8 steel (ut = 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)
Solution:
5. A cantilever beam made of cold drawn C30 steel (= 550 MPa and y = 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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Solution:
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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)
Solution:
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UNIT 4
THREDED FASTENERS
1. Write a note on bolt of uniform strength
(Jun/July2014)
Solution:
In many applications such as connecting rods, mechanical presses and power hammers, bolts
are subjected to shock or impact loads. In such cases, bolts are designed to absorb maximum
impact energy and also to resist rupture.
When bolts of the usual form are used in such situations, the maximum part of the energy
is absorbed in the threaded portion. The energy absorbed per unit volume is directly proportional
to the square of the stress developed. If the shank of a bolt is reduced to the core diameter as
shown in Fig.4.S.I, the stress 'developed in the shank increases, which in turn increases the
energy absorption in the shank, thus relieving the material near the threads. Thus, reducing
the shank area corresponding to the thread root area results in a design of a bolt of uniform
strength.
The area of the shank can alternately be reduced by drilling a hole of diameter d, as shown in
Fig. The hole dimension d1 should be such that:
Area of the Root = Area of the Shank
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The method of drilling a hole in the shank is relatively more difficult and expensive to
manufacture, that to reduce the outer diameter to the shank.
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)
Solution:
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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)
Solution:
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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)
Solution:
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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 to that of the root area of the threaded or the entire
length of the bolt is threaded.
(Dec2015)
Solution:
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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)
Solution:
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 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. Two dowel pins are provided to
take up the shear load.
(Jun/July2016)
Solution:
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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 u,= 700 MPa and yt=
460MPa as per ASME code, determine of shaft. Assume shock factor for bending and torsion
as 1.5.
(June/July 2014)
Solution:
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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. Determine the minimum length of key required if the factor of safety
is 3.
(Dec 2014)
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Solution:
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 and ii) Angle of twist of
the shaft
(June/July 2015)
Solution:
Do = 600mm
Di= 300mm
L = 5m = 500mm
N = 6000kW, n = 100rpm, F = 600kN, W = 60kN, G = 84GPa = 84 x 103 N/rnrn2
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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)
Solution:
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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 Ftc 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)
Solution:
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Considered vertical load diagram (VLD)

Taking moments about A
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6. Prove that a hollow shaft is stronger and stiffer than a solid shaft of same length, weight
and material.
(June/July 2016)
Solution:
A shaft is a rotating machine element which is used to transmit power from one place to
another. The power is delivered to the shaft by some tangential force and the resultant torque (or
twisting moment) set up within the shaft permits the power to be transferred to various
machines linked up to the shaft. In order to transfer the power from one shaft to another, the
various members such as pulleys, gears etc., are mounted on it.
(i) Strength
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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)
Solution:
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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 (ut=200MPa) with a factor of safety 6, material for shafts as carbon steel with
(yt=380MPa), with a factor of safety 2.5, material for key and bolts may be taken as steel
with (yt=400MPa in tension) and (yc=600MPa in compression) respectively and a factor of
safety 2.5. Design the coupling and given dimension.
(Dec 2014/Jan 2015)
Solution:
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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.
Solution:
(Jun/July2015)
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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)
Solution:
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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/mm 2. The angle of twist is not to exceed
1 in a length of 20 diameters. Allowable shear stress for the bolts is 13 N/mm2. The
allowable shear stress in the flange is 14 N/mm2. For the key shear stress is 40 N/mm2 and
compressive stress is 80 N/mm2.
(June/July2016)
Solution:
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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; = 60 MPa; c= 120 MPa. State how the joint
will fail and find the efficiency of the joint.
(June/July 2014)
Solution: i) Type of Joint
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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)
Solution:
i) c.g. of the world
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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)
Solution:
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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)
Solution:
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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)
Solution:
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6. Determine the maximum normal stress and the maximum shear stress in the weld shown
in Figure.
(June/July 2016)
Solution:
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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)
Solution:
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UNIT 8
POWER SCREW
1. Derive the equation for maximum efficiency of square threaded screw. (June2014/June2015)
Solution: Maximum efficiency of square thread screw
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Hence efficiency of self-locking is less than 50%. If the efficiency is more than 50%, then it is
said to be overhauling.
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)
Solution:
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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)
Solution:
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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 length of nuts for the
purpose of supporting the load.
(Dec 2015/Jan 2016)
Solution:
T 18.8 for normal series when d = 50 mm, minor dia (d 1) = 42 mm, pitch (p) = 8 mm, core
area Ac=1385mm2
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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)
Solution:
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Total frictional torque to raise load = Mts + Mtc = 500.654 x 103 Nmm
iii. Overall efficiency (fes sq thread ) E 18.33
iv. Neglecting c value of to prevent the screw for overhauling condition for overhauling
for
SQ. threads tan .
6. Write a note on power screw strength.
(June/July2016)
Solution:
A power screw is a drive used in machinery to convert a rotary motion into. a linear motion
for power transmission. It produces uniform motion and the. design of the power screw may be such
that. Either the screw or the nut is held at rest and the other member rotates as it moves axially.
In many applications such as connecting rods, mechanical presses and power hammers, power
screws are subjected to shock or impact loads. In such cases, screws are designed to absorb
maximum impact energy and also to resist rupture.
Page 63

Mech-V-Design of Machine Elements I (10me52) - Solution

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Design of Machine Elements-I

V T U - QUESTION PAPERS SOLUTION

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Design of Machine Elements-I

3. The cost of the material.

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

8. Write a note on uniform strength

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Safe load P = 20.70 KN

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

1. Derive Goodman's equation.

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

4. A Cantilever beam made of 35C8 steel (ut = 540MPa) is subjected to a completely

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

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

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I

Department of Mechanical Engineering, SJBIT, Bengaluru.

Design of Machine Elements-I