Code No: RR321401 Set No.

1
III B.Tech Supplimentary Examinations, Aug/Sep 2008
PRINCIPLES OF MACHINE DESIGN
(Mechatronics)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
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1. Compare the weights of equal lengths of hollow shaft and solid shaft to transmit a
given torque for the same maximum shear stress. The material for both the shafts
is same and inside diameter is 2/3 of outside diameter in case of hollow shaft.[16]
2. Determine the diameter of hollow shaft having inside diameter 0.5 times the out
side diameter. The permissible shear stress is limited to 200 MPa. The shaft
carries a 900 mm diameter cast iron pulley. This pulley is driven by another pulley
mounted on the shaft placed below it. The belt ends are parallel and vertical. The
ratio of tensions in the belt is 3. The pulley on the hollow shaft weighs 800 N and
overhangs the nearest bearing by 250 mm. The pulley is to transmit 35 kW at 400
rpm. [16]
3. (a) What is the importance of the dimensionless groups in the design of journal
bearings.
(b) A full-length bearing operates with the following data
Length of bearing = 150 mm
Dia of bearing = 100mm
Radial load on bearing = 25kN
Speed of journal = 250 rpm
Radial clearance = 0.045 mm

It is desired to limit minimum oil film thickness to 0.025mm. Determine a suitable

value for the viscosity of the lubricant and the power loss due to friction. [4+12]
4. Design and make a neat dimensional sketch of a muff coupling which is used to
connect two steel shafts transmitting 40kW at 350 rpm. The material for the shaft
and key is plain carbon steel for which allowable shear and crushing stress may
be taken as 40N/mm2 respectively. The material for the cast iron for which the
allowable shear stress may be assumed as 15N/mm2 . Take standard proportions.
[16]
5. A carbon steel rod of circular cross-section having σu =600MN/m2 , σy =450 MN/m2 ,
′
σe = 300 MN/m2 is subjected to a bending moment which varies between 300 to 500
Nm and axial load which varies between 5 to 10 kN. Assuming that the bending
moment and axial load are in phase determine the diameter of the rod to have a
factor of safety of 2. [16]
6. Determine the dimensions of an I-Section connecting rod for a petrol engine from
the following data:

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Code No: RR321401 Set No. 1
Diameter of the piston = 110 mm;
Mass of the reciprocating parts = 2 kg;
Length of the connecting rod from center to center = 325 mm;
Stroke length = 150 mm;
R.P.M = 1500 with possible over speed of 2500;
Compression ratio = 4:1;
Maximum explosion pressure = 2.5 N/mm2 . [16]

7. A 50 kW, 1200 rpm, high torque squirrel-cage motor is used to drive a punch press.
The speed of the punch press flywheel is 300 rpm. If the center distance is 2.5 m,
select a suitable leather belt. [16]

8. Design a pair of spur gears to drive a lobe-blower from a 120 kW motor running at
2880 rpm. With a reduction ratio of 1.6. The pitch diameter of the pinion is not
to be more than 80 mm. Drive is an enclosed one with proper lubrication. Life to
be indefinite. Light shock loads are likely. [16]
Name Material (Steel) Design compressive Design bending
stress (N/mm2 ) stress (N/mm2 )
Pinion CI 35 600 550
Gear CI 25 600 400

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Code No: RR321401 Set No. 2
III B.Tech Supplimentary Examinations, Aug/Sep 2008
PRINCIPLES OF MACHINE DESIGN
(Mechatronics)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. A shaft is subjected to a twisting moment of 5kN-m and a bending moment of

2kN-m. If the material has Sy = 330 MPa and F.S= 2, find the diameter of shaft
using

(a) Maximum shear stress theory

(b) Maximum energy of distortion theory [8+8]

2. A hoisting drum 500 mm in diameter is keyed to a shaft which is supported in

two bearings and driven through a 12:1 reduction gearing by an electric motor.
Determine the horse power of the driving motor if the maximum load of 8000 N
is hoisted at a speed of 50m/min and the efficiency of the drive be 80%. Also
determine the torque on the drum shaft and the speed of the motor. Determine the
diameter of the shaft made of machinery steel, the working stresses for which are
115 MPa in tension and 56MPa in shear. The drive gear, whose diameter is 450mm
is mounted at the end of the shaft such that it overhangs the nearest bearings by
150mm. The combined shock and fatigue factors for bending and torsion may be
taken as 2 and 1.5 respectively. [5+5+6=16]

3. (a) What are desirable properties of a bearing material?

(b) A full journal bearing of 50 mm diameter and 100 mm long has a Bearing
pressure of 1.4 N/mm2 . The speed of the journal is 900 rpm and the ratio of
journal diameter to the diametral clearance is 1000.The bearing is lubricated
with oil whose absolute viscosity at the operating temperature of 75o C may
be taken as 0.011 kg/m.s. The room temperature is 35o C. Find:
i. The amount of artificial cooling required, and
ii. The mass of the lubricating oil required if the difference between the outlet
and inlet temperature of the oil is 10 o C. Take specific heat of the oil as
1850 J/kg/o C. [5+5+6]

4. The split muff coupling is to be designed to transmit 67.5 kW at 180 rpm. Deter-
mine the diameter of the solid shaft if the permissible shear in the shaft material
is limited to 42 MPa. Assuming that the two halves of the coupling are connected
by 8 bolts, determine the diameter of each clamping bolt if the permissible tensile
stress intensity for the bolt material is limited to 70 MPa. The coefficient of friction
between the shaft and muff may be taken as 0.3. [8+8]

5. A simply supported beam has a concentrated load at the center which fluctuates
from a value of P to 4 P. The span of the beam is 500 mm and its cross-section is

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Code No: RR321401 Set No. 2
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. [16]

6. The following particulars relate to a slow speed oil engine working on four stroke
cycle:
Indicate power = 15 kW
RPM = 300
Maximum explosion pressure = 2.1 MN/m2
Mean effective pressure = 0.56 MN/m2
Design:

(a) The suitable trunk piston and piston rings

(b) The piston pin

and give a neat sketch of the piston assemble, incorporating all necessary details,
clearly indicating the materials used for each part. [8+8]

7. A 50 kW, 1200 rpm, high torque squirrel-cage motor is used to drive a punch press.
The speed of the punch press flywheel is 300 rpm. If the center distance is 2.5 m,
select a suitable leather belt. [16]

8. A spur gear drive is used to drive a camshaft by the crankshaft with a speed
reduction of 2 in a 5 kW engine. The center distance is to be not more than 160
mm. Design the drive for 10,000 hours. Crankshaft speed is 1500 rpm. Assume
pinion, gear are C 15 steel and cast iron grade 30, pressure angle 200 , Design
compressive stress for pinion, gear are 772 N/mm2 , 350 N/mm2 , design bending
stresses for pinion, gear are 85 N/mm2 , 55 N/mm2 . [16]

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Code No: RR321401 Set No. 3
III B.Tech Supplimentary Examinations, Aug/Sep 2008
PRINCIPLES OF MACHINE DESIGN
(Mechatronics)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) What are the main alloying elements in alloy steels? Why are these alloying
elements added?
(b) What is the significance of theories of failure? Discuss the most commonly
used theories. [8+8]

2. A rotating shaft is subjected to a steady bending moment of 1.5 kN-m and a

suddenly applied torque of 1 kN-m with minor shocks. Assuming allowable shear
stress for shaft material to be 55 N/mm2 , determine the diameter of the shaft.[16]

3. (a) Determine the minimum value of the basic dynamic load rating for selecting
ball bearings to give 5000 hrs of operations with not more than 10 percent
failures. The radial load is 1800 N during 90 percent of the time and 7200 N
during the remaining 10 percent. The shaft is to rotate at 150 rpm.
(b) A roller bearing is selected to withstand a radial load of 40 kN and life of
1200 hrs at 600 rpm. What load rating would you look for in searching from
manufacturers catalogue if it specifies load at speed 500 rpm and life 3000hrs.
[8+8]

4. Design a split muff coupling to transmit 10 kW at 1000 rpm. The muff is made
of FG200 CI and the shaft and the key are made of C20 steel. The coefficient of
friction between the shaft and coupling is 0.25. [16]
5. 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 [16]
6. Design a connecting rod for a petrol engine from the following data:
Diameter of the piston = 120 mm
Weight of the reciprocating part = 2.0 kg
Length of the connecting rod = 300 mm
Stroke length = 140 mm

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Code No: RR321401 Set No. 3
Speed = 2000 rpm
Maximum explosion pressure = 2.25 N/mm2 [16]

7. Select suitable V-belt for the following data.

Power to be transmitted = 50 kW
Speed of the driving pulley = 960 rpm
Velocity ratio desired = 3
Specify all the details [16]

8. Design a pair of spur gears to transmit 20 hp at a pinion speed of 1500 rpm. Trans-
mission ratio is to be 3. [16]

Name Material (Steel) Design compressive Design bending

stress (N/mm2 ) stress (N/mm2 )
Pinion 15 N I 2 Cr l M0 15 C 45 950 320
Gear C 45 500 140

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Code No: RR321401 Set No. 4
III B.Tech Supplimentary Examinations, Aug/Sep 2008
PRINCIPLES OF MACHINE DESIGN
(Mechatronics)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Differentiate between preferred numbers and rounding of numbers.

(b) What you meant by design stress. How the design stress is determined for
ductile and brittle materials. [8+8]

2. A propeller shaft transmits a twisting moment of 90 kN-m and a simultaneous

bending moment of kN-m and an axial thrust of 125 kN. If the permissible stresses
in tension and shear are 105 N/mm2 and 75 N/mm2 respectively, determine the
outer and inner diameters of the hollow shaft for which the outer diameter is 75
percent more than the inner diameter. A machinery shaft supported on bearings
3 m apart is to transmit 120 kW at 250 rpm while subjected to a bending load of
6 kN acting at a distance of 1.2 m from the left hand bearing. The material has an
allowable shear stress of 45 MPa and a bending stress of 85 MPa. Determine the
required diameter of the shaft if the transverse load is assumed steady while the
torsional load is considered to be applied suddenly. [16]

3. (a) Discuss the stable and unstable lubrication with the help of chart.
(b) A 3kN load is supported by a journal bearing of 75mm dia and 75mm long,
diametal clearance 0.05 mm and bearing is lubricated by an oil of 0.0207 Pa-s
viscosity at operating temperature. Determine the maximum speed of rotation
of bearing when it is capable of dissipating 80 watts by heat transfer. [4+12]

4. A flanged protective type coupling is required to transmit 50 kW at 2000 rpm.

Find

(a) Shaft diameter if the driving shaft is hollow with d1 /d0 = 0.6 and driven shaft
is a solid shaft. Takeτ = 100 MPa.
(b) Diameter of bolts, if the coupling uses four bolts. Take σc = σt =70 MPa
and τ = 25 MPa. Assume pitch circle diameter as about 3 times the outside
diameter of the hollow shaft.
(c) Thickness of the flange and diameter of the hub. Assume σc =100 MPa and τ
= 125 MPa.
(d) Make a neat free hand sketch of the assembled coupling showing a longitudinal
sectional elevation with the main dimensions. The other dimensions assumed
suitably. [4+4+4+4]
′
5. A hot rolled steel shaft having σu =600 MN/m2 , σy =450 MN/m2 , σe =300 MN/m2
is subjected to a variable bending moment which varies between + 300 to -200 Nm

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Code No: RR321401 Set No. 4
and a variable torque which varies between 250 to - 150 Nm. Neglecting any stress-
concentration factor, determine the diameter of the shaft to have a factor of safety
of 2. [16]

6. Design a suitable connecting rod for a car with the following data:
Piston diameter = 68 mm
Stroke length = 80 mm
Length of the connecting rod = 160 mm
Maximum explosion pressure = 3.5 N/mm2
Weight of the reciprocating part = 2.5 kg
Speed = 4000 rpm
Compression ratio = 8:1 [16]

7. A 50 kW, 1200 rpm, high torque squirrel-cage motor is used to drive a punch press.
The speed of the punch press flywheel is 300 rpm. If the center distance is 2.5 m,
select a suitable leather belt. [16]

8. A pair of 200 full depth spur gears are required to transmit 22.5 kW. The speed of
the pinion is 3000 rpm and the gear ratio of the drive is 10. The pinion of steel with
a Brinell number of 250 and the gear is made of ordinary cast iron. The number
of teeth of the pinion should be between 15 and 24. The diameter of the pinion
should be approximately 75 mm. Design the spur gear drive. [16]

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