MACHINE DESIGN

Subject Title : MACHINE DESIGN

SEM : V
Subject Code : A
Hours Per Week : 04
Hours Per Semester : 64

TOPIC ANALYSIS

Hours
SL.No Major Topics Weightage of Marks
Allotted
1 Introduction to Machine Design 04 10
2 Design of Bolts and Nuts 08 20
3 Design of Keys and Shafts 10 20
4 Design of Couplings 10 25
5 Design of Clutches 10 25
6 Design of Knuckle joint 09 20
7 Design of Engine Parts. 10 25
8 Tests 03 -
Total 64 145

NOTE: Empirical formulae should be given by the question paper setter in the question
paper only for Flange coupling and Knuckle joint.

GENERAL EDUCATIONAL OBJECTIVES

1. Understand the concepts of design.

2. Understand the use and design of Bolt and nut.
3. Understand the function and design of key
4. Understand the design of shaft under different loading conditions.
5. Know the design of muff and flange coupling.
6. Understand the design of Single & Multi plate clutches.
7. Understand the design of Knuckle joint for tensile load.
8. Understand the design of Engine cylinder, Piston, Piston pin & Piston rings.
.
 CONTENT DETAILS

1.0 Introduction to Machine Design.

Definition of Machine design- Classification of design- Design considerations in design-
General procedure of design.

2.0 Design of Bolts and Nuts

Screw thread terminology-Common types of screw fastenings-forms of screw threads-

locking devices – Designation of screw thread-Stresses due to external forces-problems.

3.0 Design of Shafts and Keys

Types of shafts- material of shaft-standard sizes of shaft-Design of shafts subjected to
bending Moment & combined bending and twisting moment-problems- Types of keys-Function of
key-Forces acting on key- Design of key based on shearing and crushing stresses.

4.0 Design of Couplings

Classification of coupling-Purpose of coupling-Design of muff and flange coupling-
problems.

5.0 Design of Clutches

Types of friction clutches- Equation for torque transmitted through clutch-problems on
Single and multi plate clutch.

6.0 Design of knuckle Joint.

Methods of failures of knuckle joint-Design procedure of knuckle joint for tensile load
-problems. .

7.0 Design of Engine parts.

Design procedure of cylinder – Design of piston, piston pin & piston rings- problems
 SPECIFIC INSTRUCTION OBJECTIVES

1.0 Introduction
1.1 Define Machine design.
1.2 Classify Machine design.
1.3 State the considerations in machine design.
1.4 Explain general procedure in Machine design.

2.0 Design of Bolts, and Nuts

2.1 Define terms concerned to screw thread terminology
2.2 List the common types of screw fastenings and their applications.
2.3 Explain different forms of screw threads.
2.4 Explain different locking devices.
2.5 explain the specification of screw threads.
2.6 Explain the stresses in screw fastening due to external loading.
2.6.1 Tensile stress.
2.6.2 Shear stress.
2.6.3 Combined shear and tensile stress.
2.7 solve simple problems on above.

3.0 Design of shaft and keys.

3.1 mention types of shaft

3.2 List types of material for shaft
3.3 Describe standard sizes of shaft.
3.4 Design of shaft subjected to twisting moment considering strength
3.5 Design of shaft subjected to twisting moment considering rigidity.
3.6 Design of shaft subjected to bending moment
3.7. Solve simple problems on above.
3.8 State the purpose of key.
3.9 Explain the types of keys with sketches.
3.10 Explain the forces acting on sunk key
3.11Solve simple problems on Design of sunk key based on shear and crushing

4.0 Design of Coupling.

4.1 State the purpose of Coupling.
4.2 List the different types of shaft couplings
4.3 Explain the requirement of good couplings
 4.5 Design of muff coupling
4.6 Design of unprotected flanged couplings
4.7 Solve simple problems on muff coupling
4.8 Solve simple problems on unprotected flanged coupling.

5.0 Design of clutches

5.1 Mention types of friction clutches.
5.2 Derive Equation for torque transmitted through clutch considering uniform pressure.
5.3 Derive Equation for torque transmitted through clutch considering uniform wear
5.4 Solve simple problems on single plate clutch.
5.5 Solve simple problems on multi plate clutch

6.0 Design of knuckle Joint

6.1 State the purpose of Knuckle joint.
6.2 Explain different methods of failures of knuckle joints
6.3 Design of knuckle joints for tensile load
6.4 Solve simple problems.

7.0 Design of Engine parts

7.1 Design of Engine Cylinder (Cylinder wall Thickness, Head thickness, Bore & length)
7.2 Design of Piston, Piston pin & piston rings.
7.3 Solve simple problems on Cylinder
7.4 Solve simple problems on Piston, Piston pin & piston rings.

Reference Books:

1. A Text book of Machine Design - R.S. Khurmi & J.K.Gupta, S.Chand publication

2. Design of Machine Elements Vol I, Vol II - J.B.K. Das, P.L. Srinivas Murthy, Sapna

Publication.

3. Introduction to Machine design - V B Bhandari, Tata- McGraw Hill Publications.

 MODEL QUESTION PAPER

Max.Marks:100 Time: 3Hrs

Note 1.Section-I is compulsory

2 Answer any two full questions from remaining sections.
3 Any missing data may be suitably assumed.
SECTION-I

1. a) Fill in the blank with appropriate word/words 1x5=5

1.The pitch diameter is the--------------diameter of an external or internal screw thread.

2.In a steam engine, the valve rod is connected to an eccentric by means of a------- joint.
3.The usual proportion for width of key is ------------.
4.The maximum normal stress theory is used for ------------ materials.
5. The coefficient of friction of clutch lining is ---------.
b) What is a Key? State its function. 05

SECTION-II

2. a) Explain Design procedure. 05

b) An eye bolt is to be used for lifting a load of 60KN. Find the nominal diameter of the bolt if
the tensile stress is not to exceed 100 MPa. Assume coarse thread. 10

3 a) Classify Design 05
b) To shafts are connected by means of a flange coupling to transmit torque of 25 N-M. the
flanges of the coupling are fastened by four 4 bolts of the same material at a radius of
30mm. find the size of the bolt if the allowable shear stress for the bolt material is 30 MPa.
10

4. a.) Sketch and explain sunk and saddle key. 05

b).A line shaft rotating at 500 rpm is to transmit 600 kW. The allowable shear stress for the shaft
material is 42N/mm2 .If the shaft carries a central load of 900 N and is simply supported
between bearings 3 m apart. Determine the diameter of the shaft. The maximum tensile
stress is not to exceed 50 MPa.- 10
SECTION-III

5. Design a cast iron unprotected flange coupling for a mild steel shaft transmitting 90 kW at 250
rpm. The allowable shear stress in the shaft is 40 MPa and the angle of twist is not to exceed
1 degree in a length of 20 diameters. The allowable shear stress in the coupling is 30 MPa. 15
6. a) Derive an equation for torque transmitted through clutch considering uniform pressure
condition 07
b) A friction clutch is required to transmit 33.12KW at 2000 rpm.It is to be of single plate disc
type With both sides of the plate effective, the pressure being applied axially by means of
springs and limited to 68.7 kpa. If the outer diameter of the plate is to be 0.305m, find the
required inner diameter of the clutch ring and the total force exerted by the springs. Assume
the wear to be uniform and µ= 0.3 08

7. Design a muff coupling which is used to connect two steel shafts transmitting 40KW at 350 rpm.
The material for the shaft and key is plane carbon steel for which allowable shear and
crushing stresses may be taken as 40MPa & 80MPa respectively. The material for the muff
is cast iron for which allowable shear stress may be assumed as 15MPa. 15

SECTION –IV

9. Design a knuckle joint to connect two mild steel rods subjected to an axial pull of 100 kN. The
allowable stress for rods and pins are 100 MPa, 130 MPa, and 60 MPa in tension, crushing and
shear respectively 15

10. A four stroke diesel engine has the following specifications

BP= 5KW, Speed = 1200 rpm, IMEP = 0.35 N/ sq mm, Mechanical efficiency= 80%,
Determine 1. Bore and length of cylinder, 2. Thickness of cylinder head 15

11. Design a cast iron piston for a single acting four stroke engine for the following data.
Bore = 100mm, Stroke = 125mm, Max gas pressure = 5 N/ sq mm, IMEP= 0.75 N/ sq mm
Mechanical efficiency = 80%, Fuel consumption = 0.15 kg/b Kw hr, HCV = 42000 KJ / Kg
Speed = 2000 rpm. Any other data required for the design may be assumed. 15
List of the formulae used to solve problems on flange coupling and knuckle joint.
Flange coupling.
If d is dia of the shaft, Outside dia of the hub=D=2d, Length of hub, L=1.5d
Pitch circle dia of bolt, D1=3d, Outside dia of flange, D2=4d, Thickness of flange, tf=0.5d
Number of bolts= 3 for d up to 40mm
= 4 for d up to 100mm
= 6 for d up to 180mm
Knuckle joint
If d is dia of the shaft, Dia of the pin=d1=d, Outer dia of eye=d2=2d,
Dia of knuckle pin head and collar=d3=1.5d, Thickness of single eye or rod end=t=1.25d
Thickness of fork=t1=0.75d, Thickness of pin head=t2=0.5d.