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Assumptions and assumed data have to be clearly stated

4 What is coupling?

10 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?

11 What is a lever?

12 What is nipping in a leaf spring? List the materials commonly used for the manufacture of the

leaf spring.

13 List any four advantages of rolling contact bearings over sliding contact bearing.

1 (a) A shaft, as shown in figure is subjected to a bending load of 3 kN, pure torque of 1000 Nm

and an axial pulling force of 15 kN. Calculate the stresses at A and B.

3 kN

A

50 mm Dia 15 kN

B

250 mm

1000 Nm

(b) Determine the diameter of a circular rod made of ductile material with an endurance limit

of 265MPa and a tensile yield strength of 350 MPa. The member is subjected to a varying

axial load from -300 kN to 700 kN and has a stress concentration factor as 1.8. Take factor

of safety as 2.

(c) An overhang crank, shown in the figure, carries a tangential load of 10 kN at the centre of

the crankpin. Find the maximum principal stress and the maximum shear stress at the

centre of the bearing.

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25

10 kN

50

125

75

40 25 100

All dimensions in mm

2 (a) A solid circular shaft is subjected to a bending moment of 3000 N-m and a torque of 10000

N-m. The shaft is made of 45C8 steel having ultimate tensile stress of 700 MPa and a

ultimate shear stress of 500 MPa. Assuming a factor of safety of 6, determine the diameter

of the shaft.

(b) A flexible coupling is used to transmit 15 kW power at 100 rpm. There are 6 pins and their

pitch circle diameter is 200 mm. The effective length of bush, the gap between two flanges

and length of the pin in contact with the right hand flange are 35, 5 and 23 mm

respectively. The permissible shear and bending stresses in the pin are 35 and 152 N/mm2.

Calculate the pin diameter by shear consideration, bending consideration.

(c) A shaft is supported by two bearings placed 1 m apart. A 600 mm diameter pulley is

mounted at a distance of 300 mm to the right of left hand bearing and this drives a pulley

directly below it with the help of belt having a maximum tension of 2.25 kN. Another

pulley 400 mm diameter is placed 200 mm to the left of right hand bearing and is driven

with the help of electric motor and belt, which is placed horizontally to the the right. The

angle of contact for both the pulleys is 180º and µ = 0.24. Dtermine the suitable diameter

for a solid shaft, allowing working stress of 60 MPa in tension and 40 MPa in shear for the

material of shaft. Assume that the torque on one pulley is equal lto that on the other pulley.

3 (a) A 50 mm diameter solid shaft is welded to a flat plate as shown in the figure. If the size of

the weld is 15 mm, find the maximum normal and shear stresses in the weld.

200 mm 10 kN

50

50 mm

Figure

(b) 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.

(c) The cylinder head of a steam engine is subjected to a steam pressure of 0.7 N/mm2. It is

held in position by means of 12 bolts. A soft copper gasket is used to make the joint leak-

proof. The effective diameter of cylinder is 300 mm. Find the size of the bolts so that the

stress in the bolts is not to exceed 100 MPa.

4 (a) 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 and the corresponding

deflection is 50 mm. The maximum torsional shear stress induced in each spring is 800

N/mm2. The spring index of each spring is 6. Assume same material for two springs and

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the modulus or rigidity of spring material is 81370 N/mm2. 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.

(b) Design a cast iron flywheel for a four-stroke IC engine developing 50 kW at 150 rpm with

75 explosions per minute. The total fluctuation of speed is limited to 0.5% of the mean on

either side. The work done during the working stroke is 1.4 times the work done during the

cycle. Assume that the flywheel stores 16/15 times the energy stored by the rim and the rim

section has width four times the depth so that the hoop stress does not exceed 4 N.mm2.

(c) 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.

5 (a) The load on a 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 60ºC and viscosity of the oil at 60ºC is 0.02 kg/m-s and the bearing

clearance is 0.25 mm.

(b) Design a connecting rod for an IC engine running at 1800 rpm and developing a maximum

pressure of 3.15 N/mm2. The diameter of the piston is 100 mm; mass of the reciprocating

parts per cylinder is 2.25 kg; length of the connecting rod 380 mm; stroke of piston is190

mm and compression ratio 6:1. Take a factor safety of 6 for the design. Take length to

diameter ratio for big end bearing as 1.3 and small end bearing as 2 and the corresponding

bearing pressures as 10 N/mm2 and 15 N/mm2. The density of material of the rod may be

taken as 8000 kg/m3 and the allowable stress in the bolts as 60 N/mm2 and the cap as 80

N/mm2. The rod is to be of I-section for which you can choose your own proportions.

Draw a neat dimensioned sketch showing provision for lubrication. Use Rankine formula

for which the numerator constant may be taken as 320 N/mm2 and the denominator

constant 1/7500.

(c) A single row deep groove 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 L10th of the bearing is

20,000 hrs. The minimum acceptable diameter of the shaft is 75 mm. Select a suitable ball

bearing for this application.

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