Ganpat University

U. V. Patel College of Engineering

Department of Mechatronics Engineering
VII- Sem. Mechanical Engineering
2ME702 - Design of Mechanical Systems
Introduction to Optimum Design
Tutorial: 4 Date:

Exa.1
In a light weight equipment, a shaft is transmitting a torque of 900 Nm and is to have a
rigidity of 90 Nm/degree. Assume a factor of safety of 1.5 based on yield stress. Design
the shaft with minimum weight. What will be the change in design for minimum cost?
Assume maximum shear stress theory of failure. Use the following data for the materials.

Material Mass Material Yield

density cost strength
(kg/m3) (Rs/N weight) (MPa)
Steel Alloy 8500 16 130
Al-Alloy 3000 32 50
Titanium Alloy 4800 480 90
Magnesium 2100 32 20
Alloy
Exa.2
In a light weight equipment, a shaft is required to transmit 40 kW power at 425 rpm. The
required stiffness of the shaft is 90 Nm/degree. The factor of safety based on yield
strength in shear is 1.5. Using the maximum shear stress theory, design the shaft with the
objective of minimizing the weight, out of the following materials:
Material Mass Material Tensile Yield Shear
density cost per unit strength Modulus
(kg/m3) weight (Rs/N) (MPa) (GPa)
Alloy Steel 7800 1.50 4500 82×103
Al-Alloy 2800 6.75 150 27×103
Titanium Alloy 4500 112 800 41×103
Magnesium Alloy 1800 7.65 100 17×103

Exa.3
A single row deep groove ball bearing operates with the following work cycles:
Radial Thrust Radial Thrust
Element Element Race Service Speed
Load, Load, Factor, Factor,
No. Time, % Rotating Factor rpm
Fr, KN Fa, KN ‘X’ ‘Y’
1 50 3.0 1.0 0.56 1.4 Inner 1.5 720
2 20 2.5 1.0 0.56 1.6 Inner 2.0 1440
3 Remaining No load No load --- --- Outer --- 720

1
 If the expected life of the bearing is 15000 hours with a reliability of 95 percent, calculate
the basic dynamic load rating of the bearing so that it can be selected from the
manufacturers catalogue based on 90 percent reliability. If there are six such bearings in
the system, what is the probability that all bearings will survive for 15000 hours?

Exa.4
Find the volume of the spring, ignoring the effect of stress concentration and curvature. A
spring supports an initial load of 244 N. The coil diameter is 6 mm and space limitations
indicate that the maximum mean diameter of the coil should be 50 mm. When the spring
is further deflected by 11 mm, the torsional shear stress must not exceed 505 MPa. Also
suggest an optimum wire diameter and number of active turns for minimum volume of
the spring material. Determine the volume ratio of the two springs. Assume modulus of
rigidity as 79 GPa.

Exa.5
Design a tensile bar of length, L = 200 mm to carry a tensile load of 5 KN for minimum
cost, out of the following materials. Take factor of safety as 2. (Ref. Fig. A.)
Material Mass density Material cost Yield strength
3
(kg/m ) (Rs / N weight) (MPa)
Steel 7500 16 130
Aluminium Alloy 3000 32 50
Titanium Alloy 4800 480 90
Magnesium Alloy 2100 32 20

Fig. (6 A)

Subject Incharge:

Dr. B. P. Patel