Code No: RR310305 Set No.

1
III B.Tech I Semester Supplimentary Examinations, November 2007
DESIGN OF MACHINE MEMBERS-I
( Common to Mechanical Engineering and Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
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1. (a) Select suitable materials for the manufacture of the following:

i. Machine tool spindle
ii. valve spring
iii. condenser tubes
iv. connecting rod.
(b) What are alloy steels? Discuss the effect of adding different alloying elements
in steel? [8+8]

2. (a) Draw the stress strain diagrams of

i. ductile materials and
ii. brittle materials
(b) A steel saw blade 1 mm thick is bent into an arc of a circle of 50 cm radius.
Determine the flexural stresses induced and the bending moment required to
bend the blade which is 15 mm wide. Take E = 2.1X105 N/mm2 . [6+10]

3. (a) Explain notch sensitivity.

(b) A circular bar of 0.5 m 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 factor 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. [6+10]

4. (a) Enumerate the different types of riveted joints.

(b) Two plates 16 mm thick are joined by a double riveted lap joint. The pitch
of each row of rivets is 90 mm. The rivets are 25 mm in diameter. The
permissible stresses are 140 MPa in tension, 80 MPa in shear and 160 MPa in
crushing. Find the efficiency of the joint. [6+10]

5. A bracket carrying a load of 15 KN is to be welded as shown in Figure5. Find the

size of weld required if the allowable shear stress is not to exceed 80 MPa.

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Code No: RR310305 Set No. 1

Figure 5
[16]

6. (a) Describe the purpose of gib in cotter joint? What are the applications of cotter
joints?
(b) Design a knuckle joint to transmit 140 kN, with permissible stresses in tension;
shear and compression are 75 Mpa ; 60 Mpa and 150 Mpa respectively.[6+10]

7. (a) Explain the effect of keyway on the strength of a shaft.

(b) A shaft is required to transfer 43kW of power at 600rpm. The outside diam-
eter must not exceed 50mm and the maximum shear stress is not to exceed
70N/mm2 . Find out the dimensions of hollow and solid shaft, which would
meet these requirements. Also compare their weights. [6+10]

8. (a) Describe, with the help of neat sketches, the types of various shaft couplings,
mentioning the uses of each type.
(b) Design a muff coupling to connect two shafts transmitting 40KW at 120rpm.
The permissible shear and crushing stress for the shaft ank key material (mild
steel) are 30Mpa and 80Mpa respectively. The material of muff is cast Iron
with permissible shear stress of 15Mpa. Assume that the maximum torque
transmitted is 25 percent greater than mean torque. [6+10]

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Code No: RR310305 Set No. 2
III B.Tech I Semester Supplimentary Examinations, November 2007
DESIGN OF MACHINE MEMBERS-I
( Common to Mechanical Engineering and Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. Enumerate the most commonly used engineering materials and state atleast one
important property and application of each. [16]

2. (a) Briefly explain shear stress and shear strain?

(b) Calculate the diameter of the solid shaft to transmit 50 kW at 180 rpm. If
the angle of twist in a length of 4 meters is not to exceed 0.40 . The allowable
stress in the material is 70 MPa and modulus of rigidity is 84 GPa. [4+12]

3. (a) Explain the effect of the following factors on the type of fatigue failure.
i. Strain rate
ii. Type of material
iii. Manner of loading
(b) A steel connecting rod is subjected to a completely reversed axial load of 1,600
MPa. Suggest the suitable diameter of the rod using a factor of safety 2. The
ultimate tensile strength of the material is 1,100 MPa and yield strength 930
MPa. Neglect column action and the effect of stress concentration. [6+10]

4. (a) Enumerate the different types of riveted joints.

(b) Two plates 16 mm thick are joined by a double riveted lap joint. The pitch
of each row of rivets is 90 mm. The rivets are 25 mm in diameter. The
permissible stresses are 140 MPa in tension, 80 MPa in shear and 160 MPa in
crushing. Find the efficiency of the joint. [6+10]

5. (a) What are the relative advantages and disadvantages of welded joints over
riveted joints.
(b) A 125 X 95 X 10 mm angle is joined to a frame by two parallel fillet welds
along the edge of 125 mm length. If the angle is subjected to a static load of
180 kN, find the length of weld at the top and bottom. The allowable static
load per mm weld length is 430N. [6+10]

6. (a) A feather key is 12mm wide and is to transmit 700N-m torque from a 400mm
diameter shaft. The steel key has an allowable stress in tension and com-
pression of 120Mpa and an allowable shear stress of 575Mpa. Determine the
required length of key. If the key dimensions are reversed as 9mm wide and
12mm deep, what would have been the required length of key for same load
and material.

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Code No: RR310305 Set No. 2
(b) Design a cotter joint to withstand an axial load varying from 45kN in tension
to 45 kN in compression. The allowable for the steel used in the joint are
60Mpa in tension; 70 Mpa in crushing; 45 Mpa in shear. [6+10]

7. A hollow shaft of 0.5m outside diameter and 0.3m inside diameter is used to drive
a propeller of a marine vessel. The shaft is mounted on bearings 6 meter apart and
it transmits 5600 KW at 150 rpm. The maximum axial propeller thrust is 500 kN
and the shaft weighs 70 kN determine the maximum shear stress developed in the
shaft and the angular twist between the bearings. [16]

8. Design a protective type of cast iron flange coupling for a steel shaft transmitting
22 KW at 175 rpm and having an allowable shear stress of 38 N/mm2 . The working
stress in the bolts should not exceed 30 N/mm2 . Assume that the same material
is used for the shaft and key and that the crushing stress is twice the value of its
shear stress. The maximum torque is 30% greater than the full load torque. The
shear stress for cast iron is 12 N/mm2 . [16]

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Code No: RR310305 Set No. 3
III B.Tech I Semester Supplimentary Examinations, November 2007
DESIGN OF MACHINE MEMBERS-I
( Common to Mechanical Engineering and Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. (a) Select suitable materials for the manufacture of the following:

i. Machine tool spindle
ii. valve spring
iii. condenser tubes
iv. connecting rod.
(b) What are alloy steels? Discuss the effect of adding different alloying elements
in steel? [8+8]

2. (a) Briefly explain shear stress and shear strain?

(b) Calculate the diameter of the solid shaft to transmit 50 kW at 180 rpm. If
the angle of twist in a length of 4 meters is not to exceed 0.40 . The allowable
stress in the material is 70 MPa and modulus of rigidity is 84 GPa. [4+12]

3. (a) Explain the following methods of reducing stress concentration

i. Drilled holes
ii. Using large fillet radius
iii. Added grooves
(b) A shaft is made of steel [ultimate tensile strength 700 MPa and yield point
420 MPa is subjected to a torque varying from 200N m] anti-clockwise to 600
N m clockwise. Calculate the diameter of the shaft if the factor of safety is 2
and it is based on the yield point and the endurance strength in shear.[6+10]

4. Two lengths of mild steel tie rod having width 200 mm are to be connected by
means of Lozenge joint with two cover plates to withstand a tensile load of 180
KN. Completely design the joint, if the permissible stresses are 80 MPa in tension,
65 MPa in shear and 160 MPa in crushing. Draw a neat sketch of the joint.[12+4]

5. (a) Explain the following terms with respect to screwed joints:

i. Major diameter
ii. Minor diameter
iii. Pitch
iv. Lead
v. Single and multi-start threads.

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Code No: RR310305 Set No. 3
(b) Two shafts are connected by means of a flange coupling to transmit 260 watts
at 100 rpm. The flanges of the coupling are fastened by four bolts of same
material at a radius of 30 mm. Find the size of the bolts if the allowable shear
stress for the bolt material is 30 MPa. [5+11]

6. (a) Describe the purpose of gib in cotter joint? What are the applications of cotter
joints?
(b) Design a knuckle joint to transmit 140 kN, with permissible stresses in tension;
shear and compression are 75 Mpa ; 60 Mpa and 150 Mpa respectively.[6+10]

7. (a) What type of stresses are induced in shafts?

(b) A solid circular shaft is subjected to a bending moment of 3000N-m and a
torque of 10,000N-m. The shaft is made of 45C8 steel having ultimate tensile
stress of 700Mpa and a ultimate shear stress of 500Mpa. Assuming a factor
of safety as 6, determine the diameter of shaft. [6+10]

8. Design and draw a bush type flexible flange coupling to transmit 15Hp at 960 rpm
allowable shear stress for the shaft and key may be taken as 53.5N/mm2 . the shear
stress in the bolts should not exceed 35N/mm2 . the bearing pressure between the
bush and coupling should be 2N/mm2 . [12+4]

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Code No: RR310305 Set No. 4
III B.Tech I Semester Supplimentary Examinations, November 2007
DESIGN OF MACHINE MEMBERS-I
( Common to Mechanical Engineering and Production Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
⋆⋆⋆⋆⋆

1. The following results were obtained in a tensile test on a mild steel specimen of
original diameter 20 mm and gauge length 40 mm.
Load at limit of proportionality = 80 kN
Extension at 80 kN load = 0.048 mm
Load at yield point = 85 kN
Maximum load = 150 kN
When the two parts were fitted together after being broken, the length was found
to be 55.6 mm and the diameter at the neck was 15.8 mm. Calculate young’s
modulus, yield stress, ultimate tensile stress, percentage elongation and percentage
reduction in area. [16]

2. (a) Define factor of safety for :

i. Ductile materials and
ii. Brittle materials
(b) Discuss the various stresses and the corresponding deformations that exist in
machine components under load. [6+10]

3. (a) Explain the effect of the following factors on the type of fatigue failure
i. Range of imposed stress
ii. Surface treatement
(b) A stepped shaft transmits a torque varying from 800 N m to 1200 N m. The
ratio of diameter is 1.5 and the stress concentration factor is 1.2. Determine
the diameter of the shaft for an infinite life for a design factor of safety 1.8.
The ultimate tensile strength of the material of the shaft is 600 MPa. Yield
stress of the material is 450 MPa. Consider the size effect and surface finish
effect. [6+10]

4. (a) What do you understand by the term riveted joint? Explain the necessity of
such a joint.
(b) A double riveted lap joint is made between 15-mm thick plates. The rivet
diameter and pitch are 25 mm and 75 mm respectively. If the ultimate stresses
are 400 MPa in tension, 320 MPa in shear and 640 MPa in crushing, find the
minimum force per pitch which will rupture the joint.
If the above joint is subjected to a load such that the factor of safety is two,
find out the actual stresses developed in the plates and the rivets. [6+10]

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Code No: RR310305 Set No. 4
5. A bracket carrying a load of 15 KN is to be welded as shown in Figure5. Find the
size of weld required if the allowable shear stress is not to exceed 80 MPa.

Figure 5
[16]

6. (a) Describe the design procedure of sunk keys.

(b) Design a cotter joint to withstand an axial load varying from 50kN in tension
to 50kN in compression. The allowable for the steel used in the joint are
60Mpa in tension; 70 Mpa in crushing; 45 Mpa in shear. [6+10]

7. (a) What type of stresses are induced in shafts?

(b) A solid circular shaft is subjected to a bending moment of 3000N-m and a
torque of 10,000N-m. The shaft is made of 45C8 steel having ultimate tensile
stress of 700Mpa and a ultimate shear stress of 500Mpa. Assuming a factor
of safety as 6, determine the diameter of shaft. [6+10]

8. (a) Discuss the function of coupling. Give at least three practical applications?
(b) Design a bushed pin type flexible coupling for connecting two shafts when Hp
to be transmitted = 50
Speed of the shaft = 100rpm
Diameter of the shaft = 50mm.
The bearing pressure in the rubber bush and allowable stress in the pins are
to be limited to 0.45N/mm2 and 25N/mm2 respectively. Sketch the coupling.
[6+10]

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