AVS ENGINEERING COLLEGE, SALEM-3

UNIT -IV

ME6503Design of Machine Elements

Question banK
Part­A (answer all questions) 
1. What are the applications of concentric spring? (APR­2010)
2. Two springs of stiffness K1 and K2 arc connected in series. What is the stiffness of
connection? (APR­2010)
3. When two concentric springs of stiffness 100 N/mm and 50 N/mm respectively are
subjected to an axial load of 750 N, what will be the deflection of each spring? (APR­2009)
4. Give some of the materials used for springs. (NOV­2008)
5. What is nipping of leaf spring. (APR 2016)
6. What is stiffness of spring(APR 2016)
7. Define semi elliptical spring .State any two important applications of leaf spring. (APR 2008)
8. What is the effect of change in spring index on wahl’s factor and on the stress induced in a helical compression
spring? (APR 2015)
9. What is wahl’s factor? Why its required? . (APR 2013)
10. State the purpose of using concentric springs. (APR 2015)
11. Define free length and spring index (APR­2011)
12. What is meant by surge in spring (NOV­2008)
13. Distinguish Between Close And Open Coiled Spring(NOV­2014)
14. Write formula for natural frequency of spring? (NOV­2012)
15. What is the purpose of flywheel that is used in an IC engine? (NOV­2013)
16. Why are flywheels used in presses? (NOV­2014)
17. How Does The Function Of Flywheel differ from governor? (NOV­2012)
18. Define coefficient of fluctuation of speed and coefficient of fluctuation of energy. (NOV­2014)
19. What type of external force acting connecting rod(NOV­2012)
20. Why I section preferred in connecting rod(NOV­2009)

Part­B (Answer All questions) 
1. A concentric spring is used as a valve spring in a heavy duty diesel engine. It consists of two helical compression springs
having the same free length and same solid length. The composite spring is subjected to a maximum force of 6000 N und
the corresponding deflection in 50 mm. The maximum torsional shear stress induced in each spring is 800 N/mm 2. The
spring index of each spring is 6. Assume same materials for two springs and the modulus of rigidity of spring materials is
81370 N/m2. The diametral clearance between the coils is equal to the difference between their wire diameters.Calculate :
(i) The axial force transmitted by each spring, (ii) Wire and mean coil diameters of each spring,(iii) Number of active
coils in each spring.(APR­2010)
2. A helical compression spring made of oil tempered carbon steel is subjected to a load which varies from
400N to 1000 N. the spring index is 6 and design factor safety is 1.25. if the yield stress in shear is
770MPa and endurance stress in shear is 350 MPa, find size of the spring wire, diameter of spring,
number of turns of spring and free length of the spring. The compression of the spring at the maximum
load is 30mm.take G=80KN/mm2. (APR 2016)
3. Design a helical compression spring to sustain an axial load of 4 KN. The deflection is 80 mm. C is 6.the
shear strss is not exceed 350 MPa.G=81GPa. (APR 2015)
4. Design a spring for spring loaded safety valve for the following condition :
Operating pressure = 1 MPa; Diameter of the valve seat = 110 mm;Design shear stress for the spring = 360 MPa;G = 82 GPa
The spring is to be kept in the casing of 130 mm inner diameter and 400 mm long. The spring should be at maximum lift of 6
mm when the pressure is 1.08 MPa. (APR 2008)
5. Design a helical spring for a spring loaded safety valve (Ramsbottom safety valve) for the following conditions :
Diameter of valve seat = 65 mm ; Operating pressure = 0.7N/mm 2; Maximum pressure when the valve blows off freely =
0.75N/mm2; Maximum lift of the valve when the pressure rises from 0.7 to 0.75 N/mm 2 = 3.5 mm ; Maximum allowable
stress = 550 MPa ; Modulus of rigidity = 84 kN/mm 2; Spring index = 6. Draw a neat sketch of the free spring showing
the main dimensions. (NOV­2012)
6. Design and draw a valve spring of a petrol engine for the following operating
conditions : Spring load when the valve is open = 400 N; Spring load when the valve is closed = 250 N;Maximum
inside diameter of spring = 25 mm;Length of the spring when the valve is open= 40 mm; Length of the spring
when the valve is closed= 50 mm; Maximum permissible shear stress = 400 MPa(APR 2010)
 7. Design a closed coil helical spring for a boiler safety valve which is required to blow off steam at the pressure of 1.5
N/mm2. The diameter of the valve is 50 mm. The initial compression of the spring is 40 mm and the lift is limited to 20
mm. (APR 2013)

8. A close coiled helical spring has plain ends and is to fit over a 25mm dia rod. When a compressive force of
100N is applied to the spring it compresses by 50mm. if the spring has preferred wire dia of 4mm,and the
spring material maximum allowable shear streass of 180MN/m 2 and G=81GPa, determine  mean coil dia,
the diametral clearance between the spring and rod,number of coil in the spring, solid length.   (APR
2014)
9. A helical valve spring is to be designed for an operating load range of 90 N to 135 N. The deflection of the spring for this
load range is 7.5 mm. assuming a spring index of 10, a permissible shear stress of 80 N/mm 2 for the material and
modulus of rigidity of 0.8 X 10 5 N/mm2. Determine the dimensions of the spring. Sketch the spring with dimensions
indicated. (NOV­2008)
10. A helical compression spring is used to absorb the shock. The initial compression of the spring is 30 mm and it is further
compressed by 50 mm while absorbing the shock. The spring is to absorb 250 J of energy during the process. The spring
index can be taken as 6. The spring is made of patented arid cold drawn steel wire with ultimate strength of 1500 N/mm 2
and modulus of rigidity of 81370 N/mm2. The permissible shear stress for the spring wire should be taken as 30% of the
ultimate tensile strength. Design the spring and calculate:(i) Wire diameter (ii) Mean coil diameter (iii) Number of active
turns (iv) Free length; and Pitch of the turns. (APR­2012)
11. (a) Design a leaf spring for a truck to the following specifications:
Maximum load on the spring = 100 kN Number of spring =4 Material = Cr Va steel (ultimate strss =1380MPa) steel Permissible
tensile stress = 600 N/mm2 . Span of spring = 1000 mm with a central band = 150mm Permissible deflection = 100 mm Young's
modulus of the spring = 206 x 103 MPa. Assume 2 full length leaves and 6 graduated leaves. Assume FOS =2 (APR 2015)
b) A truck spring has 12 number of leaves, two of which are full length leaves. The spring supports are 1.05 m apart and the
central band is 85 mm wide. The central load is to be 5.4 kN with a permissible stress of 280 MPa. Determine the thickness and
width of the steel spring leaves. The ratio, of the total depth to the width of the spring is 3. Also determine the deflection of the
spring.(APR­2009)
12 . a) A semi elliptical laminated vehicle spring to carry a load of 6000 N is to consist of seven leaves 65 mm wide, two of
the leaves extending the full length of the spring. The spring is to be 1.1 m in length and attached to the axle by two U-
bolts 80 mm apart. The bolts hold the central portion of the spring so rigidly that they may be considered equivalent to a
band having a width equal to the distance between the bolts. Design stress for spring material is 350 MPa. Design the
spring.
b) A locomotive spring has an overall length of 1.1 m and sustained a load of 75 kN at its centre. The spring has 3 full length
leaves and 15 graduated leaves with a central band of 100 mm wide. All leaves are to be stresses to 420 N/mm 2. When fully
loaded the ratio of the spring depth to width is to be approximately 2. Take E = 2.1 X 105 N/mm2.
(i) Determine width and thickness of the leaves. Determine the initial space that should be provided between the full
length and graduated leaves before the band load is applied. What load is exerted on the band after the spring is assembled? .
(APR­2009) .(NOV­2014)
13 A single cylinder double acting steam engine delivers 185 kW at 100 r.p.m. The maximum fluctuation of
energy per revolution is 15 per cent of the energy developed per revolution. The speed variation is limited to
1 per cent either way from the mean. The mean diameter of the rim.is 2.4 m. Design and draw two views of
the flywheel. (NOV­2013) (APR­2016)

14 .Design and draw a cast iron flywheel used for a four stroke I.C engine developing 180 kW at 240 r.p.m. The hoop or
centrifugal stress developed in the flywheel is 5.2 MPa, the total fluctuation of speed is to be limited to 3% of the mean speed.
The work done during the power stroke is 1/3 more than the average work done during the whole cycle. The maximum torque
on the shaft is twice the mean torque. The density of cast iron is 7220 kg/m3. (NOV-2012)

15. The turning moment diagram of a multi-cylinder engine is drawn with a scale of (l mm= 1°) on the abscissa and (1 mm = 250
N-m) on the ordinate. The intercepted areas between the torque developed by the engine and the mean resisting torque developed
by the engine and the moan resisting torque of the machine, taken in order from one end are -350, +800, -600, +900, -550, +450
and -650 mm2. The engine is running , at a mean speed of 750 rpm and the coefficient of speed fluctuations is limited to 0.02. A
rimmed flywheel made of gray cast iron FG 200 (ρ= 7100 kg/m3) is provided. The spokes, hub and shaft are assumed to contribute
10% of the required moment of inertia. The rim has rectangular cross section and the ratio of width to thickness is 1.5. Determine
the dimensions of the rim. (APR­2010) (APR­2011)

16. A punching press pierces 35 holes per minute in a plate using 10 kN-m of energy per hole during each revolution. Each
piercing takes 40 per cent 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 800 mm diameter and turning at 210 r.p.m. Find the power of the electric motor if overall efficiency of
the transmission unit is 80 per cent. Design a cast iron flywheel to be used with the punching machine for a coefficient of
steadiness of 5, if the space considerations limit the maximum diameter to 1.3 m. Allowable shear stress in the shaft material = 50
MPa Allowable tensile stress for cast iron = 4 MPa Density of cast iron = 7200 kg / m3. (APR­2009)

17. Determine the dimensions of an I-section connecting rod for a petrol engine from the following data:
Diameter of the piston = 110 mm; Mass of the reciprocating parts = 2 kg; Length of the connecting rod from centre to centre =
325 mm; Stroke length = 150 mm; R.P.M. = 1500 with possible overspeed of 2500; Compression ratio = 4 : 1; Maximum
explosion pressure = 2.5 N/mm2. (APR­2011)

Determine the dimensions of an I-section connecting rod for a petrol engine from the following data:
Diameter of the piston = 100 mm; Mass of the reciprocating parts = 2 kg; Length of the connecting rod from
centre to centre = 325 mm; Stroke length = 150 mm; R.P.M. = 1500 with possible overspeed of 2500;
Compression ratio = 4 : 1; Maximum explosion pressure = 2.5 N/mm2. (APR­2011)
Load on a hydrodynamic full journal bearing is 30 KN. The dia and speed of the shaft are 150 mm and
1200 rpm respectively. Diametral clearance 0.2 mm. sommerfield number is 0.631.L/D = 1:1. Calculate
temperature rise of oil, quantity of the oil,heat generated and type of oil. .(APR­2015)

1) Design   a   journal   bearing   for   12   MW,   1000   rpm   steam   turbine,   which   is   supported   by   two
bearings.   Take   atmospheric   temp   as   16   C   and   operating   temperature   of   oil   as   60   C   assumes
viscosity of oil as 23 Ns/m2. .(MAY­2016)

2) A Journal bearing 150mm dia and 300mm long carries a radial load of 9KN at 1200 rpm. the
diametral clearance is 0.075mm. If 6KW is being lost in friction, what is viscosity of the oil used at
given operating temperature? (NOV­2012)

3) A 50mm dia journal bearing rotates at 1500rpm, L/D= 1, radial clearance is 0.05mm, minimum
film thickness = 0.01mm.calculate the maximum radial load that the journal bearing can carry and
still operate hydrodynamic condition. For this load calculate power lost in friction and increase in
oil temperature. Assume Hg= Hd, absolute viscosity 20X103 Pas, Sp.gravity of oil is 0.8, sp.heat of
oil 2.1KJ/KgC.(NOV­2014)

4) Following data is given for a 360° hydrodynamic bearing. Journal diameter = 100 mm, Radial
clearance = 0.12 mm, Radial load = 50 kN, Bearing length = 100 mm, Journal speed = 1440 rpm
and   viscosity   of   lubricant   =   16CP.   Calculate   (i)   Minimum   film   thickness   (ii)   Co­efficient   of
friction and (iii) Power lost in friction. .(NOV­2007)

5) Design a journal bearing for a centrifugal pump from the following data :
Load on the journal = 20 kN, Speed of the journal = 900 rpm, Type of oil is SAE 10 for which the
absolute viscosity at 55°C = 0.017 kg/m­s; Ambient temperature of oil = 15.5°C, Maximum bearing
pressure for the pump = 1.5 N/mm 2  Calculate mass of the lubricating oil required for artificial
cooling, if rise of temperature of oil be limited 10°C. Heat dissipation coefficient = 1232 W/m 2/ C.
(NOV­2013)

6)  Design a journal bearing for a centrifugal pump with the following data :
Diameter of the journal = 150 mm, Load on bearing = 40 kN , Speed of journal = 900 r.p.m.
(APR­2014)

7) The radial and thrust load acting on a bearing are 7400N and 3500N respectively. The shaft
dia   is   130mm   and   it   rotates   at   1600   rpm.   the   outer   ring   is   stationary.   load   is   smooth,
8hrs/day/for life of 15000hrs. i) select a deep groove ball bearing. ii) find the rated 90% life of
bearing   of   selected   bearing.iii)   compute   the   probability   of   the   selected   bearing   surviving
17000hours. Take b=1.34.(NOV­2014) .(MAY­2012)

8) Select a bearing for a 40mm dia shaft rotates at 400 rpm. due to bevel gear mounted on the
shaft, the bearing will have to withstand a 5000N radial load and 3000N thrust load. The life of
bearing expected to be atleast 1000hrs. .(APR­2014)
 9) Select suitable ball bearing deepgroove ball bearing for supporting a radial load of 10KN and
an axial load of 3 KN for a life of 4000 hours at 800 rpm. select from series 63. Calculate the
expected life of the selected bearing. .(MAY­2016) (NOV­2012)

10) A single­row deep­groove ball bearing is subjected to a radial force of 8 kN and a thrust force of
3 kN. The shaft rotates at 1200 rpm. The expected life L10 of the bearing is 20,000 hr. The
minimum acceptable diameter of the shaft is 75 mm. Select a suitable ball bearing for this
application.(NOV­2008

11) Find the rated load of a deep groove ball bearing for the following load cycle.
S.NO RADIAL  AXIAL  % OF TIME
LOAD (N) LOAD(N)

1 3000 1000 15

2 3500 1000 20

3 3500 10 30

4 500 2000 35

Also find the 90% life of ball bearing if bearing used is  6207 with dynamic  capacity

19620N.(NOV­2014)

12) A ball bearing is operated on work cycle consisting of three parts a radial load of 3000N at1440
rpm for one quarter cycle, a radial load of 5000N at 720 rpm for one half cycles, and radial load
of 2500N at 1440 rpm for remaining cycle. The expected life of bearing is 100000hrs.calculate
the dynamic load carrying capacity of the bearing.
             Explain in detail rolling contact bearing failure­causes and remedies. .(NOV­2009)
  
13)  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 40hours/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. (APR­2008)

AVS ENGINEERING COLLEGE, SALEM-3

Internal TEST-II

Year/Branch III/Mechanical- B Date/Session:23.08.16/A.N

Subject Code/Name ME6503 Design of Machine Elements Duration: 90min

Part­A (answer all questions) (5*2=10 Marks)

1. In what situation is flexible coupling used?

2. Differentiate between keys and splines.
3. List any four advantages of rolling contact bearings over sliding contact bearings.
4. What is a Journal bearing? List any two applications.
5. What are the effects of clearance on the performance of a bearing?

Part­B (Answer All questions) (4*10=40 Marks)
6. Design a journal bearing for a centrifugal pump from the following data :
Load on the journal = 20 kN, Speed of the journal = 900 rpm, Type of oil is SAE 10 for which the absolute viscosity at 55°C =
0.017 kg/m-s; Ambient temperature of oil = 15.5°C, Maximum bearing pressure for the pump = 1.5 N/mm 2 Calculate mass of the
lubricating oil required for artificial cooling, if rise of temperature of oil be limited 10°C. Heat dissipation coefficient = 1232
W/m2/ C.

     7) Design a journal bearing for a centrifugal pump with the following data :
Diameter of the journal = 150 mm, Load on bearing = 40 kN , Speed of journal = 900 r.p.m

   8) Design a muff coupling to transmit a power of 35 KW from a shaft running at120 rpm.Assume suitable material and stresses.

   9). 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 40hours/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.

AVS ENGINEERING COLLEGE, SALEM-3

Internal TEST-I

Year/Branch III/Mechanical- B Date/Session:28.07.16/A.N

Subject Code/Name ME6503 Design of Machine Elements
Duration: 90min

Part-A (answer all questions) (5*2=10 Marks)

7. What are the steps in machine design process?  
8. What is Gerber theory?
9. How to reduce the stress concentration? 
10. What is meant by Endurance limit and eccentricity?
11. What is stress concentration?

Part­B (Answer All questions) (4*10=40 Marks)
1) A steel rod is subjected to a reversed axial load of 180 kN. Find the diameter of the rod
for a factor of safety of 2. Neglect column action. The material has an ultimate tensile
 strength of 1070 MPa and yield strength of 910 MPa. The endurance limit in reversed
bending   may   be   assumed   to   be   one­half   of   the   ultimate   tensile   strength.   Other
correction   factors   may   be   taken   as   follows:   For   axial   loading   =   0.7;   For   machined
surface = 0.8 ; For size = 0.85 ; For stress concentration = 1.0.

         2)  An overhang crank with pin and shaft is shown in Fig. A tangential load of 15 kN acts
on the crank pin.                 Determine the maximum principal stress and the maximum shear
stress at the centre of the crankshaft bearing.

3)  Design a protective type of cast iron flange coupling for a steel shaft transmitting 15kW at
200 rpm and having an allowable shear stress of 40 N/rnm 2. The working stress in the bolt
should not exceed 30 N/mm2. Assume that the same material is used for shaft and key that the
crushing stress is twice the value of its shear stress. The maximum torque is 25% greater than
the full load torque. The shear stress for cast iron is 14 N/mm 2.

4.  A simply supported beam has a concentrated load at the centre which fluctuates from a
value of P to 4 P.The span of the beam is 500 mm and its cross­section is circular with a
diameter of 60 mm. Taking for the beam material an ultimate stress of 700 MPa, a yield
stress of 500 MPa, endurance limit of 330 MPa for reversed bending, and a factor of safety of
1.3, calculate the maximum value of P. Take a size factor of 0.85 and a surface finish factor of
0.9.  

AVS ENGINEERING COLLEGE, SALEM-3

Internal TEST-I

Year/Branch III/Mechanical- A Date/Session:18.07.14/F.N

Subject Code/Name Design of Machine Elements
Duration: 2 HRS

Part-A (answer all questions) (10*2=20 Marks)

1. List any four type of fits?
2. Write down general procedure in machine design?
3. Define stress concentration factor.
 4. What is meant by fatigue?
5. How to reduce the stress concentration?
6. What do you mean by factor of safety??
7. Differentiate between hardness and toughness  of materials.
8. Give the different failure theories and the type of materials for which these theories are
applicable?
9. Define­ Tolerance? What are the types of tolerance?
10. How to reduce the stress concentration?   .

Part­B (Answer any Three) (3*10=30 Marks)
2) A)  A   beam   of   uniform   rectangular   cross­section   is   fixed   at   one   end   and   carries   an
electric   motor   weighing   400   N   at   a   distance   of   300   mm   from   the   fixed   end.   The
maximum  bending  stress  in the  beam  is  40   MPa. Find  the width  and depth  of the
beam, if depth is twice that of width. 

   b) A mild steel shaft of 50 mm diameter is subjected to a bending moment of 2000 N­m and 
a torque T. If the yield point of the steel in tension is 200 MPa, find the maximum value of 
this torque without causing yielding of the shaft according to 1. The maximum principal 
stress theory; 2. The maximum shear stress theory; 

3) A circular bar is simply supported with a span of 0.5mand is subjected to a concentrated
cyclic load at its mid span. The load varies from a minimum value of 20KN to maximum
value of 45 KN. Decide upon the diameter of the bar taking a factor of safety of 1.5 and
factor of 0.85 and 0.89 respectively for size effect and surface finish. Take often following
values for material properties. Ultimate strength = 650N/mm 2, Yield strength = 450N/mm 2
Endurance strength =350N/mm2

4)  A steel rod is subjected to a reversed axial load of 180 kN. Find the diameter of the rod
for a factor of safety of 2. Neglect column action. The material has an ultimate tensile
strength of 1070 MPa and yield strength of 910 MPa. The endurance limit in reversed
bending   may   be   assumed   to   be   one­half   of   the   ultimate   tensile   strength.   Other
correction   factors   may   be   taken   as   follows:   For   axial   loading   =   0.7;   For   machined
surface = 0.8 ; For size = 0.85 ; For stress concentration = 1.0.

5) A hot rolled steel shaft is subjected to a torsional moment that varies from330 N­m
clockwise to 110 N­m counterclockwise and an applied bending moment at a critical
section varies from 440 N­m to – 220 N­m. The shaft is of uniform cross­section and no
keyway is present at the critical section. Determine the required shaft diameter. The
material has an ultimate strength of 550 MN/m 2 and yield strength of 410 MN/m 2. Take
the endurance limit as half the ultimate strength, factor of safety of 2, size factor of
0.85 and a surface finish factor of 0.62.

GATE QUESTIONS
A pulley is keyed to a shaft midway between two anti­friction bearings. The bending moment at the pulley varies from – 170
N­m to 510 N­m and the torsional moment in the shaft varies from 55 N­m to 165 N­m. The frequency of the variation of the
loads is the same as the shaft speed. The shaft is made of cold drawn steel having an ultimate strength of 540 MPa and a
yield strength of 400 MPa. Determine the required diameter for an indefinite life. The stress concentration factor for the
keyway in bending and torsion may be taken as 1.6 and 1.3 respectively. The factor of safety is 1.5. Take size factor = 0.85
and surface finish factor = 0.88.

A steel cantilever beam, as shown in Fig. is subjected to a transverse load at its end that varies from 45 N up to 135 N down
as the axial load varies from 110 N (compression) to 450 N (tension). Determine the required diameter at the change of
section for infinite life using a factor of safety of 2. The strength properties are as follows:
Ultimate strength = 550 MPa
Yield strength = 470 MPa
Endurance limit = 275 MPa

A beam of uniform rectangular cross-section is fixed at one end and carries an electric motor weighing 400 N at a distance of 300
mm from the fixed end. The maximum bending stress in the beam is 40 MPa. Find the width and depth of the beam, if depth is
twice that of width.

A mild steel shaft of 50 mm diameter is subjected to a bending moment of 2000 N-m and a torque T. If the yield point of the steel
in tension is 200 MPa, find the maximum value of this torque without causing yielding of the shaft according to 1. The maximum
principal stress; 2. The maximum shear stress;

A bracket, as shown in Fig. 5.43, is bolted to the framework of a machine which carries a load P. The cross-section at 40 mm from the fixed end
is rectangular with dimensions, 60 mm × 30 mm. If the maximum stress is limited to 70 MPa, find the value of P.
1. A simply supported beam has a concentrated load at the centre which fluctuates from a value of P to 4 P.
The span of the beam is 500 mm and its cross-section is circular with a diameter of 60 mm. Taking for the
beam material an ultimate stress of 700 MPa, a yield stress of 500 MPa, endurance limit of 330 MPa for
reversed bending, and a factor of safety of 1.3, calculate the maximum value of P. Take a size factor of 0.85
and a surface finish factor of 0.9. (10)

2) It is required to design a rigid type of flange coupling to connect two shafts. The input shaft transmits
37.5 kW power at 180 rpm to the output shaft through the coupling. The service factor for the application is
1.5, i.e. the design torque is 1.5 times of rated torque. Select suitable materials for various parts of the
coupling, design the coupling and specify the dimensions of its components. (10)

3) A pulley is keyed to a shaft midway between two bearings. The shaft is made of cold drawn steel for
which the ultimate strength is 550 MPa and the yield strength is 400 MPa. The bending moment at the
pulley varies from – 150 N-m to + 400 N-m as the torque on the shaft varies from – 50 N-m to + 150 N-m.
Obtain the diameter of the shaft for an indefinite life. The stress concentration factors for the keyway at the
pulley in bending and in torsion are 1.6 and 1.3 respectively.
Take the following values:
Factor of safety = 1.5
Load correction factors = 1.0 in bending, and 0.6 in torsion
Size effect factor = 0.85
Surface effect factor = 0.88

4) Design a knuckle joint to connect two circular rods subjected to an axial tensile force of 50 kN. The rods
are co-axial and a small amount of angular movements between their axes is permissible. Design the joint
and specify the dimensions of its components. Select suitable materials for the parts. (10)
 AVS ENGINEERING COLLEGE, SALEM-3
Internal TEST-I

Year/Branch III/Mechanical- A Date/Session:18.07.14/F.N

Subject Code/Name Design of Machine Elements
Duration: 2 HRS

Part-A (answer all questions) (10*2=20 Marks)

11. List any four type of fits?
12. Write down general procedure in machine design?
13. Define stress concentration factor.
14. What is meant by fatigue?
15. How to reduce the stress concentration?
16. What do you mean by factor of safety??
17. Differentiate between hardness and toughness  of materials.
18. Give the different failure theories and the type of materials for which these theories are
applicable?
19. Define­ Tolerance? What are the types of tolerance?
20. How to reduce the stress concentration?   .

Part­B (Answer any Three) (3*10=30 Marks)
 6) A)  A   beam   of   uniform   rectangular   cross­section   is   fixed   at   one   end   and   carries   an
electric   motor   weighing   400   N   at   a   distance   of   300   mm   from   the   fixed   end.   The
maximum  bending  stress  in the  beam  is  40   MPa. Find  the width  and depth  of the
beam, if depth is twice that of width. 

   b) A mild steel shaft of 50 mm diameter is subjected to a bending moment of 2000 N­m and 
a torque T. If the yield point of the steel in tension is 200 MPa, find the maximum value of 
this torque without causing yielding of the shaft according to 1. The maximum principal 
stress theory; 2. The maximum shear stress theory; 

7) A circular bar is simply supported with a span of 0.5mand is subjected to a concentrated
cyclic load at its mid span. The load varies from a minimum value of 20KN to maximum
value of 45 KN. Decide upon the diameter of the bar taking a factor of safety of 1.5 and
factor of 0.85 and 0.89 respectively for size effect and surface finish. Take often following
values for material properties. Ultimate strength = 650N/mm 2, Yield strength = 450N/mm 2
Endurance strength =350N/mm2

8)  A steel rod is subjected to a reversed axial load of 180 kN. Find the diameter of the rod
for a factor of safety of 2. Neglect column action. The material has an ultimate tensile
strength of 1070 MPa and yield strength of 910 MPa. The endurance limit in reversed
bending   may   be   assumed   to   be   one­half   of   the   ultimate   tensile   strength.   Other
correction   factors   may   be   taken   as   follows:   For   axial   loading   =   0.7;   For   machined
surface = 0.8 ; For size = 0.85 ; For stress concentration = 1.0.

9) A hot rolled steel shaft is subjected to a torsional moment that varies from330 N­m
clockwise to 110 N­m counterclockwise and an applied bending moment at a critical
section varies from 440 N­m to – 220 N­m. The shaft is of uniform cross­section and no
keyway is present at the critical section. Determine the required shaft diameter. The
material has an ultimate strength of 550 MN/m 2 and yield strength of 410 MN/m 2. Take
the endurance limit as half the ultimate strength, factor of safety of 2, size factor of
0.85 and a surface finish factor of 0.62.

GATE QUESTIONS
A pulley is keyed to a shaft midway between two anti­friction bearings. The bending moment at the pulley varies from – 170
N­m to 510 N­m and the torsional moment in the shaft varies from 55 N­m to 165 N­m. The frequency of the variation of the
loads is the same as the shaft speed. The shaft is made of cold drawn steel having an ultimate strength of 540 MPa and a
yield strength of 400 MPa. Determine the required diameter for an indefinite life. The stress concentration factor for the
keyway in bending and torsion may be taken as 1.6 and 1.3 respectively. The factor of safety is 1.5. Take size factor = 0.85
and surface finish factor = 0.88.
A steel cantilever beam, as shown in Fig. is subjected to a transverse load at its end that varies from 45 N up to 135 N down
as the axial load varies from 110 N (compression) to 450 N (tension). Determine the required diameter at the change of
section for infinite life using a factor of safety of 2. The strength properties are as follows:
Ultimate strength = 550 MPa
Yield strength = 470 MPa
Endurance limit = 275 MPa

A beam of uniform rectangular cross-section is fixed at one end and carries an electric motor weighing 400 N at a distance of 300
mm from the fixed end. The maximum bending stress in the beam is 40 MPa. Find the width and depth of the beam, if depth is
twice that of width.

A mild steel shaft of 50 mm diameter is subjected to a bending moment of 2000 N-m and a torque T. If the yield point of the steel
in tension is 200 MPa, find the maximum value of this torque without causing yielding of the shaft according to 1. The maximum
principal stress; 2. The maximum shear stress;

A bracket, as shown in Fig. 5.43, is bolted to the framework of a machine which carries a load P. The cross-section at 40 mm from the fixed end
is rectangular with dimensions, 60 mm × 30 mm. If the maximum stress is limited to 70 MPa, find the value of P.

1. A simply supported beam has a concentrated load at the centre which fluctuates from a value of P to 4 P.
The span of the beam is 500 mm and its cross-section is circular with a diameter of 60 mm. Taking for the
beam material an ultimate stress of 700 MPa, a yield stress of 500 MPa, endurance limit of 330 MPa for
reversed bending, and a factor of safety of 1.3, calculate the maximum value of P. Take a size factor of 0.85
and a surface finish factor of 0.9. (10)

2) It is required to design a rigid type of flange coupling to connect two shafts. The input shaft transmits
37.5 kW power at 180 rpm to the output shaft through the coupling. The service factor for the application is
1.5, i.e. the design torque is 1.5 times of rated torque. Select suitable materials for various parts of the
coupling, design the coupling and specify the dimensions of its components. (10)
3) A pulley is keyed to a shaft midway between two bearings. The shaft is made of cold drawn steel for
which the ultimate strength is 550 MPa and the yield strength is 400 MPa. The bending moment at the
pulley varies from – 150 N-m to + 400 N-m as the torque on the shaft varies from – 50 N-m to + 150 N-m.
Obtain the diameter of the shaft for an indefinite life. The stress concentration factors for the keyway at the
pulley in bending and in torsion are 1.6 and 1.3 respectively.
Take the following values:
Factor of safety = 1.5
Load correction factors = 1.0 in bending, and 0.6 in torsion
Size effect factor = 0.85
Surface effect factor = 0.88

4) Design a knuckle joint to connect two circular rods subjected to an axial tensile force of 50 kN. The rods
are co-axial and a small amount of angular movements between their axes is permissible. Design the joint
and specify the dimensions of its components. Select suitable materials for the parts. (10)