DESIGN OF MACHINE ELEMENTS

QUESTION BANK
PART A
1. What are the steps in machine design process?
2. What are Unilateral and Bilateral Tolerances?
3. Under what circumstances flexible coupling are used?
5. Differentiate joint and coupling.
6. Classify the rivet heads according to IS specifications.
7.What are various theories of failure?
8.Differentiate Hole based system and Shaft based system?
9. Define working stress.
10. What are the points to be considered in deciding the factor of safety ?
11.Why are welded joints preferred over riveted joints?
12.What are the types of welded joints?
13.Write down the formula for the strength of single transverse fillet weld
14.Differentiate with a neat sketch the fillet welds subjected to parallel loading and transverse
loading.
15.State any two reasons for preferring hollow shafts over solid shaft.
16.What types of stresses are developed in the key?
17.Define (a) Spring Index (b) Spring rate.
18.What is the main function of a flywheel in an engine?
19.List the basic assumptions used in the theory of hydrodynamic lubrication.
20. Sketch fluid film lubrication.
21.Write down the formula for finding equivalent twisting moment.
22.Define the term critical speed.
23.What is a key?
24.What are the types of keys?
25.What are the advantages of welded joints over riveted joints?
26. How are bolts designated? Give examples.
27.What do you mean by Optimum design?
28.What is stress concentration factor?
29.Differentiate between keys and splines.
30.Two springs K1 and K2 are connected in series.What is the stiffness of connections?
31.What is the main function of a flywheel in an engine?
32.What is meant by journal bearing?
33.Explain the term dynamic load carrying capacity of rolling contact ball bearing?
34.Classify the roller hearings.What is load rating?
36.State any points to be considered for selection of bearings.
37.What is bearing?Classify the types of bearings.
38.. List any six types of bearing materials.
PART B

11. A shaft is shown in fig is subjected to the bending load of 3kN, pure torque of 1000Nm
and the axial pulling force of 15kN. Calculate Stresses at A and B.

12. The C-frame of 100kN capacity press is shown in below fig. The material of the frame is
grey cast iron and the factor of safety is 3. Determine the dimension s of frame.

13. The frame of a punch press is shown in Fig. Find the stresses at the inner and outer
surface at section X-X of the frame, if W = 5000 N.

14. A circular bar 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 1.5, 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.
15.Design and draw a cast iron flange coupling for a mild steel shaft transmitting 90KW at
250rpm. The allowable shear stress in the shaft is 40MPa and the angle of twist is not to
exceed 10mm in a length of 20mm diameters. The allowable shear stress in the coupling bolt
is 30MPa.
16.An electric generator rotates at 200rpm and receives 300KW from the driving engine. The
armature of the generator is 60cm long and located between bearing 120cm center to center.
Owing to the combined weight of armature and magnetic pull, the shaft is subjected to
9000kg acting at right angles to the shaft. The ultimate stress for the shaft is 4480kg/cm2 and
shear stress is 3920kg/cm2.Find the diameter of the shaft for a factor of safety of 6.
17. A pulley is keyed to a shaft midway between two anti-friction bearings. The bending
moment at the pulley varies from 170 N-m to 510 N-m and the torsional moment in the

shaft varies from 55 N-m to 165 N-m. 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.
18.A hot rolled bar of steel is subjected to a torsional load varying from-150N-m to 450N-m.
Determine the required diameter of the bar using a factor of safety of 1.7. Properties of the
material may be assumed as follow.
Ultimate tensile stress = 450MPa
Yield stress = 300MPa (16)
19.Design a shaft to transmit power from an electric motor to a lathe head stock through a
pulley by means of a belt drive. The pulley weighs 200 N and is located at 300 mm from the
centre of the bearing. The diameter of pulley is 200 mm and the maximum power transmitted
is 1 kW at 120 rpm. The angle of lap of the belt is 180 and coefficient of friction between the
belt and the pulley is 0.3. The shock arid fatigue factors for bending and twisting are 1.5 and
2 respectively. The allowable shear stress in the shaft may be taken as 35 MPa.
(b) Two 35 mm shafts are connected by a flanged coupling. The flanges are fitted with 6 bolts
on 25 mm bolt circle. The shafts transmit a torque of 800 N-m at 350 rpm. For the safe
stresses mentioned below, calculate (i) diameter of bolts. (ii) thickness of flanges, (iii) key
dimensions (iv) hub length and (v) power transmitted. Safe stress for shaft material 63 MPa,
Safe stress for bolt material 56 MPa, Safe stress for cast iron coupling 10 MPa and Safe stress
for key material 46 MPa.
20.Design a knuckle joint to transmit 150 kN. The design stresses may be taken as 75 MPa in
tension, 60 Mpa in shear and 150 Mpa in compression.
21. Design a shaft to transmit power from an electric motor to a lathe head stock through a
pulley by means of a belt drive. The pulley weighs 200 N and is located at 300 mm from the
centre of the bearing. The diameter of pulley is 200 mm and the maximum power transmitted
is 1 kW at 120 rpm. The angle of lap of the belt is 180 and coefficient of friction between the
belt and the pulley is 0.3. The shock arid fatigue factors for bending and twisting are 1.5 and
2 respectively. The allowable shear stress in the shaft may be taken as 35 MPa.
22.The load on the journal bearing is 150 kN due to turbine shaft of 300 mm diameter
running at 1800 rpm. Determine the following. (i) Length of the bearing if the allowable
bearing pressure is 1.6 N/mm2 and (ii) Amount of heat to be removed by the lubricant per
minute if the bearing temperature is 60C and viscosity of the oil at 60C is 0.02 kg/m-s and
the bearing clearance is 0.25 mm.

23. A Rigid steel bracket subjected to a vertical force of 13.5kN is shown in below fig. It is
fastened to a vertical stanchion by means of four identical bolts. Determine the size of the
bolts by maximum shear stress theory. The maximum permissible shear stress in any bolt is
limited to 200 N/mm2
(16)

24. Design a bushed-pin type of flexible coupling to connect a pump shaft to a motor shaft
transmitting 32 kW at 960 r.p.m. The overall torque is 20 percent more than mean torque.
Draw neat sketch of the coupling. The material properties are as follows :
(a) The allowable shear and crushing stress for shaft and key material is 40 MPa and 80 MPa.
(b) The allowable shear stress for cast iron is 15 MPa. (c) The allowable bearing pressure for
rubber bush is 0.8 N/mm2. (d) The material of the pin is same as that of shaft and key.
25.A rectangular cross-section bar is welded to a support by means of fillet welds as shown in
fig (i). Determine the size of the welds, if the permissible shear stress in the weld is limited to
75 MPa.

Fig. (i) All dimensions are in mm

26.A locomotive semi-elliptical laminated spring has an overall length of 1 m and sustains a
load of 70 kN at its centre. The spring has 3 full length leaves and 15 graduated leaves with a
central band of 100 mm width. All the leaves are to be stressed to 400 MPa, when fully
loaded. The ratio of the total spring depth to that of width is 2. Take young modulus is 210
kN/mm2. Determine (i) the thickness and width of the leaves (ii) the initial gap that should be
provided between the full length and graduated leaves before the band load is applied and
(iii) the load exerted on the band after the spring is assembled.

27.Find the maximum shear stress induced in the weld of 6 mm size when a channel, as
shown in Fig., is welded to a flat plate and loaded with 20 kN force at a distance of 200 mm.

28. A steam of effective diameter 300mm is subjected to a steam pressure of 1.5N/mm2.The

cylinder head is connected by 8 bolts having yield point 330MPa and endurance limit at
240MPa.The bolts are tightened with an initial per load 1.5 times the steam load. A soft
copper gasket is used to make the joint leak proof. Assuming a factor of safety 2, find engine
size of bolt required.The stiffness factor for copper gasket may be taken as 0.5
29.Determine the length of the weld run for a plate of size 120mm wide and 15mm thick to
be welded to another plate by means of (1) A single transverse weld (2) Double parallel fillet
welds when the joint is subjected to variable loads. Assume (Tensile stress =70MPa, shear
stress=56MPa.
30.A multi cylinder engine is to run at a constant load at a speed of 600 rpm. On drawing the
crank effort diagram to scale of 1 mm = 250 N-m and 1 mm = 3, the areas in square mm
above and below the mean torque line were measured and found to be in order +160, 172,
+168, 191, +197 and 162. The speed is to be kept with in 1% of the mean speed of the
engine. Determine the moment of inertia of the flywheel. Also determine suitable dimensions
for cast iron flywheel with a rim whose breadth is twice its radial thickness. The density of
cast iron is 7250 kg/m3, and its working stress in tension is 6 MPa. Assume that the rim
contributes 92% of the flywheel effect.
31. The load on the journal bearing is 150 kN due to turbine shaft of 300 mm diameter
running at 1800 rpm. Determine the following. (i) Length of the bearing if the allowable
bearing pressure is 1.6 N/mm2 and (ii) Amount of heat to be removed by the lubricant per
minute if the bearing temperature is 60C and viscosity of the oil at 60C is 0.02 kg/m-s and
the bearing clearance is 0.25 mm.
32.A closely coil helical spring is made of 10mm diameter steel wire, the coil consisting of 10
complete turns with a mean diameter of 120mm.The springs carries an axial pull of
200N.Determine also deflection in the spring, its stiffness and strain energy stored by it if the
modulus of rigidity of the material is 80KN/mm2
33.Design a cantilever leaf spring to absorb 600N-m energy without exceeding a deflection of
150mm and a stress of 800N/mm2 The length of the spring is 600mm. The material of the
spring is steel.Take,E=200KN/mm2

34. 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 = 0.7 N/mm2;
Maximum pressure when the valve blows off freely = 0.75 N/mm2; Maximum lift of the
valve when the pressure rises from 0.7 to 0.75 N/mm2 = 3.5 mm ; Maximum allowable stress
= 550 MPa ; Modulus of rigidity = 84 kN/mm2; Spring index = 6. Draw a neat sketch of the
free spring showing the main dimensions.
35.Design a mild steel connecting rod with an I-section for a single cylinder IC engine from
the following data. Diameter of the piston is 0.104 m; weight of reciprocating parts is 18.2 N;
length of connecting rod-center to center is 0.314 m; stroke length is 0.14 m; speed of the
engine is 1500 rpm; Maximum explosion pressure is 2.28 MPa. Assume that the maximum
thrust takes place at TDC during the explosion stroke. Assume also any missing data.
36. A journal bearing is to be designed for a centrifugal pump for the following data: Load
on the journal = 12 kN ; Diameter of the journal = 75 mm ; Speed = 1440 rpm ; Atmospheric
temperature of the oil = 16C ; Operating temperature of the oil = 60C; Absolute viscosity of
oil at 60C = 0.023 kg/m-s. Give the systematic design of the sliding contact bearing.
37. Determine the dynamic load carrying capacity of a deep-groove ball bearing with the
least bore size and which is required to resist a radial load of 4KN,and an axial thrust load of
3KN.The shaft rotates at 1400 rpm. The bearing is required to be in an operation for 1200
hours, with 90% reliability.
38.A single row deep groove ball bearing operating at 2000 rpm is acted by a 10KN radial
load and 8KN thrust load. The bearing is subjected to a light shock load and the outer ring is
rotating. Determine the rating life of the bearing.
39.A full journal bearing of 50mm diameter and 100mm long has a bearing pressure of
l.4N/mm2.The speed of the journal is 900rpm and the ratio of journal diameter to the
diametric clearance is 1000. The bearing is lubricated with oil, whose absolute viscosity at
the operating temperature of 75C may be taken as 0.011 kg/m-s. The room temperature is
35oC. Find,
(1) The amount of artificial cooling required.
(2)The mass of lubricating oil required, if the difference between the outlet and
inlet temperature of the oil is 10C. Take specific heat of oil as 1850J/Kg/0C.
40. A 150mm diameter shaft supporting a load of 10KN has a speed of 1500rpm.The shaft
run in whose bearing length is 1.5 times the shaft diameter. If the diametric clearance of
bearing is 0.15mm and the absolute viscosity of the oil at the operating temperature is 0.011
Kg/m-s. Find the power wasted in friction.