UNIT-1

STEADY STRESSES AND VARIABLE STRESSES IN MACHINE MEMBERS TWO MARKS: 1. Define Design and explain the design process. 2. What is innovative design? 3. Explain a method of reducing cost of the final product from the design perspective. 4. What is Optimization? What are the methods for optimization? 5. Define factor of safety. What factors dictate the selection of factor of safety? 6. Explain in detail the maximum shear stress theory. 7. Differentiate between hardness and toughness of materials. 8. Explain creep and resilience. 9. List the various types of loads and explain. 10. Distinguish between different types of variable stresses.

TEN MARKS: 1. Find the size of a hole that can be punched in a 20mm thick steel plate
having ultimate shear strength of 300N/mm. Maximum permissible the compressive stress in the punch material is 1200N/mm.

2. A square ties bar 20x20mm cross-section carries a load. It is attached to a

bracket by 6 bolts. Calculate the bolt diagram if the maximum stress in the tie bar is 150N/mm and in the bolts is 75N/mm.

3. A mild steel shaft of 50mm diameter is subjected to a bending moment of

2x10N-mm and a torque without causing yielding of the shaft according to ) Maximum principal stress ) Maximum shear stress ) Maximum distortional energy theories. 4. A bar of circular cross section is subjected to alternating tensile forces varying from 200kN to 500kN. Materials ultimate tensile strength is

900Mpa, endurance limit is 700Mpa. Determine the diameter of the bar using safety factor of 3.5 related to ultimate strength and 4 related to endurance limit. Stress concentration factor is 1.65 use Goodman criteria. 5. A steel bar is subjected to a reversed axial load of 180kN. Find the diameter of the bar for a design factor of 2. Ultimate tensile strength 1070N/mm yield strength 910N/mm. Endurance limit in bending is half of ultimate tensile strength. Use the following data. Load factor 0.7, surface finish factor 0.8, size factor 0.85, and stress concentration factor 1. 6. Determine the diameter of a circular rod made of ductile material with an endurance limit is 25Mpa and tensile yield strength of 350Mpa. The member is subjected to a varying axial load from- 300kN to 700kN and has a stress concentration factor is 1.8. Take factor of safety as 2. 7. A cast iron pulley transmits 12kW at 330rpm. The diameter of the pulley is 1.3m and it has four straight arms of elliptical cross section in which the major axis is twice the minor axis. Determine the dimensions of the arm allowable bending stress is 18Mpa. 8. A hollow shaft of 40mm outer diameter and 25mm inner diameter is subjected to a twisting moment of 120N-m, simultaneously, it is subjected to an axial thrust of 10kN and a bending moments of 80N-m. Calculate the maximum compressive and shear stresses. 9. A hot rolled bar of steel is subjected to a torsional load varying from-150Nm to 450Nm. Determine the required diameter of the bar using a factor os safety of 1.7. properties of the material may be assumed as follows. Ultimate tensile stress = 450Mpa. Yield stress = 300Mpa 10. A steel rod made of C 35 steel, is subjected to a reversed axial load of 150kN. Determine the required diameter of the using a factor of safety of 1.75. Neglect stress concentration and notch sensitivity.

UNIT 2
DESIGN OF SHAFTS AND COUPLINGS
TWO MARKS: 1. Why a hollow shaft has greater strength and stiffness than solid shaft of equal weight? 2. Why is maximum shear stress theory used for shaft? 3. What is the significance of slenderness ratio in shaft design? 4. What types of stress are developed in the key? 5. Differentiate between keys and splines. 6. Classify crankshaft. 7. What are the stress involved in crank pin? 8. Under what circumstances flexible couplings are used? 9. What is couplings? 10.What is the material used for flange or flange coupling?

TEN MARKS:
1. A shaft is subjected to reversal bending moment of 80Nm and variable torque that varies from +10Nm to 50Nm during each cycle. Assuming that the shaft is made of C-40steel. For a design factor of 2, determine the required diameter of shaft. 2. Compare the weight, strength and stiffness of a hollow shaft of same internal diameter as that of a solid shaft. The inside diameter of the hollow shaft is being 0.7 times the external diameter. Both the shaft has same material and length. 3. A shaft 30mm diameter is transmitting power at a maximum shear stress of 80N/mm. if a pulley is connected to the shaft by means of key, find the dimensions of the key so that the stress in the key is not to exceed 50N/mm and the length of key is 4 times of width of the key. 4. Design the rectangular sunk key for a shaft of 50mm diameter. The shearing and crushing stress in the key are limited to 40N/mm and 70N/mm.

5. Design a sunk key for 60mm diameter shaft to transmit 25kW at 500rpm. The permissible stresses in the key material are 60N/mm in shearing and 150N/mm in crushing. 6. A 50kW power at 250rpm is transmitted from 60mm diameter shaft by means of kennedy keys. The keys are made of C45 steel having yield strength of 370N/mm and factor safety is 2.5. Design the key. 7. Design an overhung crankshaft for an I.C.engine for the following data. Stroke = 250mm; cylinder bore = 200mm; length of the connecting rod = five times the crank radius; maximum gas pressure 2.2N mm gas pressure hen the tor ue is maximum 1.1N mm crank angle hen the tor ue is maximum 30 . 8. Design a center crank for an I.C.engine with bore of 250mm and stroke of 300mm. Length of the connecting rod is 50mm. Maximum gas pressure 250N cm . he maximum tor ue is at 35 of crank angle hen the gas pressure is 1.2Mpa. Design stress is 65N/mm. Distance between the main bearings of the crank is 350mm. 9. Two shafts 80mm diameter is to be connected by means of two cast iron flange couplings. The allowable shearing stress of the bolt materials is 45N/mm. While that of the shaft materials is 55N/mm. Find the size of the bolts to be used. Check the bolts for the induced crushing stress. 10. A marine type flange coupling is used to transmit 4.5MW at 200rpm. The allowable shear stress in the shaft and bolts may be taken as 45N/mm. Determine the shaft diameter and the diameter of the bolts as per Indian standard.

UNIT 3
DESIGN OF TEMPORARY AND PERMANENT JOINTS TWO MARKS:
1. How is a bolt designed? Give example. 2. What stresses act on screw fastening? 3. Why are weld joints preferred over riveted joints? 4. State the main principle of fusion welding. 5. When will the edge preparation be needed? 6. What are the advantages and limitations of cotter joints? 7. What is a gib? Why is it provided in a cotter joint? 8. What is caulking and fullering? 9. Name the possible modes of failure of riveted joint. 10.Differentiate between key and cotter.

TEN mark:
1. A plate 100mm wide and 12.5mm thick is to be welded to another plate by means of single transverse and double parallel fillet welds. Determine the length of weld run in each case, if the joint is subjected to varying loads. The recommended design stress in tension is not to exceed 70N/mm 2 and in shear 56N/mm2 for static loading. 2. A spherical pressure vessel is made of 8mm steel plate hemisphere, butt welded together. Determine the allowable internal pressure to which the tank may be subjected, if the permissible stress were limited to 70N/mm2. 3. A double riveted lap joint is to be made between 6mm plates. Safe working stress for plates and rivet materials are c = 80N/mm2, t=60N/mm2 ,=50N/mm2. Design the joint.

4. Design a longitudinal riveted joints for a boiler of 1.5m inside diameter and steam pressure =2.2N/mm2. The safe stress in tension, crushing and shear respectively are 75, 120 and 60N/mm2. Type of joints is triple riveted butt joint with unequal cover plate.also draw the two views of joint. 5. Design a triple riveted, double strap of unequal width butt joint for the longitudinal seam of a boiler at inside diameter 1250mm and working pressure of 1.25N/mm2. Allowable stresses in shear, tension and crushing are 60, 75, 120 N/mm2.sketch the joint. 6. A knuckle joint is to transmit a force of 140kN. Allowable stresses in tension , shear and compression are 75N/mm2, 65N/sq.mm,40N/sq.mm respectively. Design the joint. 7. Design a cotter joint with one gib to transmit force of 50KN along a rod of square section assume that gib ,rod and cotter are made of same material with the following allowable stresses. Under tension =20MPa Compression = 50MPa Shear = 15 MPa 8. Design a knuckle joint to with stand a tensile load of 70KN using steel with the following permissible stresses (in tension) = 60 MPa (in crushing) = 72 MPa T(in shear) = 48 MPa 9. Describe welding specification with its elements and sketches. 10. Classify the riveted joints detail with sketches.

UNIT-4 DESIGN OF ENERGY STORING ELEMENTS 2 MARKS: 1. what is spring? 2. What are various types of springs? 3. Classify helical spring? 4. Define leaf spring? 5. Define Belleville spring? 6. What are conical springs? 7. What is buckling spring? 8. What is flywheel effect? 9. State any two types of flywheel? 10.Define surging of springs? 10 MARKS: 1. From a toy gun a bullet of 1.5N is fired. The bullet travels a distance of 12m.the compression of spring when the gun is loaded is 125mm and bore of the barrel is 22mm . design a suitable spring. 2. A helical spring made of square steel wire is subjected to an axial load of 400N.the allowable shear stress in spring material is 310N/sq.mm and the spring index is 6.the modulus of rigidity is 0.8*10 5N/sq.mm.determine size of square section,mean diameter of coil, no. Of active turns if the deflection is 10mm. 3. A helical spring of rate 12N/mm is mounted on the top of the spring of rate 8N/mm.find the force required to give a deflection of 50mm. 4. A Belleville spring is made of 3mm steel metal sheet with an outside dia of 125mm and the dia ratio as 2.5. the spring is dished 4.5mm. the maximum

stress produced at the inner edge is 560N/sq.mm.determine deflection,load that may be safely carried.check the stress produced at the outer edge. 5. A torsion spring is made of 6mm monel metal wire wound with an inside dia of 45mm.assumig a safety factor. Find (a) the maximum force which can be applied with a 55mm leverage and the corresponding deflection in degrees if spring has 4.5 coils. 6. An automobile semi elliptical spring is 1.5m long carries a load 8000N. The spring cosists of 10 leaves with 2 full length leaves. All leaves are 50mm wide. Find the thickness of the leaves.also find the maximum stresses induced for a deflection of 60mm. 7. Design a semi-elliptical for the rear axle of a car. The load on the rear axle of the car is 10KN. The span is 1m long and the width of clamp is 100mm. In all,12 leaves are used out of which two are main leaves and the remaining are graduated leaves. Assume suitable material. 8. Design a rim type C.I fly wheel for an I.C engine to store 10,000N-m of energy the speed of engine is to be 5002.5%.assume suitable stress valve. 9. What are various types of spring ,explain any three? 10.What are various types of spring material eplain each?

UNIT - 5
DESIGN OF BEARING AND MESCELLANEOUS ELEMENTS TWO MARKS:
1. 2. 3. 4. 5. What is bearing? Classify the types of bearing. What is the nature of contact involved in a ball bearing element? Define antifriction bearings. What are the types of rolling contact bearings?

6. State the components of rolling contact bearings. 7. What are the several types of radial ball bearing? 8. What are the types of thrust ball bearings? 9. Classify the roller bearings. 10.What is meant by life of anti-friction bearings?

TEN MARKS:
1. Design a hydrodynamic full journal bearing for a centrifugal pump of 250mm diameter of 250mmx250mm to support a load of 25kN. Speed of the journal is 1440rpm. 2. A 25BC02 deep groove ball bearing is to operate at 1300rpm and carries 6000N radial load and 4500N thrust load. The subjected to a light shock load. Determine the rating life of the bearing. 3. Select a bearing for a 45mm diameter shaft rotates at 500rpm. Due to a bevel gear mounted on the shaft, the bearing will have to withstand a 4500N radial load and a 2500N thrust load. The life of the bearing expected to be at least 6000hr. 4. Design a journal bearing for a centrifugal pump with the following data: Diameter of the journal = 125mm Load on bearing = 50kN Speed of journal = 400rpm 5. Design a journal bearing for 20MW, 200rpm steam turbine, which is supported by two bearings. Take the atmospheric temperature as 23 c and operating temperature of oil is 70 c. Assume viscosity of oil as 20 centistokes. 6. If in above bearing, the radial clearance is only 0.12mm then what should be the absolute viscosity of oil to be used. 7. A journal bearing 120mm diameter and 300mm long carries a radial load of 10kN at 1250rpm. The diameteral clearance is 0.8mm. if 8kw is being lost in friction, what is the viscosity of the oil used at given operating temperature? 8. Design a journal bearing for centrifugal pump for the following data: Load on the journal = 15kN Diameter of the journal = 80mm

Speed = 1500rpm Atmosphere temperature = 20 c Operating temperature of oil = 65 c Absolute viscosity of oil at 60 c = 26 centipoise 9. The following data refer to a journal bearing: Diameter of the journal = 110mm Length of the journal = 180mm Load = 30kN Speed = 300rpm C/D = 0.001 determine the coefficient of friction and heat generated. 10. What are different types of bearing , explain brifly.