# Code No: R05312401

Set No. 1

III B.Tech I Semester Regular Examinations, November 2007 DESIGN OF MACHINE ELEMENTS (Automobile Engineering) Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks ⋆⋆⋆⋆⋆ 1. (a) What is meant by hole basis system? (b) What is meant by shaft basis system and why is it preferred? [8+8] 2. (a) Explain the Modiﬁed Goodman’s line theory for designing the components subjected to fatigue loads (b) A thin wall cylindrical pressure vessel of mean diameter of 60 cm is subjected to internal pressure varying from 0 to 40 MPa. Find the required thickness of the pressure vessel based on yield point of 400 MPa, endurance limit of 22 Mpa, and a factor of safety of 3. Use Soderberg criterion of failure. [6+10] 3. (a) How is the allowable stress calculated for a riveted joint subjected to alternating type of load. (b) The end of a receiver, cylindrical in shape is closed by a lap joint using rivets. The maximum pressure in the receiver is 1 MPa. The axial length of the receiver is limited to 2 m while its storing capacity is 2 m3 . Design the suitable lap joint giving a neat sketch. The permissible stresses in shear and crushing of rivets may be taken as 30 MPa and 70 MPa. The permissible tensile stress for the plate material is 80 MPa. [6+10] 4. (a) What is Woodruﬀ key? Give its applications.
1 (b) A shaft and a key are made of the same material and the key width is 4 of the shaft diameter. Consider shear only, determine the minimum length of the key in terms of the shaft diameter. The shearing strength of the key material is 60% of its crushing strength. Determine the thickness of the key to make the key equally strong in shear and crushing. [6+10]

5. (a) Under What circumstances, concentric springs are preferred? (b) A rail carriage weighing 200kN and running at 5 km/hour is brought to rest by four buﬀer springs of close coiled helical type during connection with another carriage which is already at rest. The mean coil diameter is 5 times the wire diameter. The deﬂection of each spring is 220 mm, to bring the carriage to rest. Safe shear stress for the spring material is 400 N/mm2 . Calculate the maximum load on the spring, diameter of wire and coil, number of turns and free length of spring. Assume the ends of spring are squared and ground. Take G= 0.8×104 N/mm2 . [2+14] 6. (a) Explain the various types of lubrication? 1 of 2

Code No: R05312401

Set No. 1

(b) A 310 deep groove ball bearing has a work cycle with 1000r.p.m for one-third of the time, 2000 r.p.m for the next one =third of the time, and 4000 r.p.m for the last one-third of the time. The outer race of the bearing rotates. Assume light shock condition. The radial load is 3.5kN and axial load is 2kN. Determine the expected average life in hours, if the basic dynamic capacity of the bearing is 47 kN. [4+12] 7. Design the Cross-head for double acting steam engine having cylinder bore of 30cm, stroke 60cm, steam pressure at the port and back pressure of 0.9MPa and 0.1MPa respectively. The engine is running at 120 rpm. Ratio of Connecting rod to crank length is 4. Gudgeon pin is made of bronze with allowable bearing pressure of 7MPa and bolts of carbon steel with safe stress of 100MPa. Forged steel is used for all other parts and take σt =80MPa and σs =60MPa for it. Safe bearing pressure for the slide ranges between 0.3MPa to 0.5MPa. [16] 8. Design an aluminum alloy piston for a single acting four stroke engine for the following data: Cylinder bore = 400mm Stroke = 375mm Maximum gas pressure = 9 M Pa Break mean eﬀective pressure = 2MPa Fuel consumption = 0.22kg/kW/hr Speed =50rev/min. ⋆⋆⋆⋆⋆

[16]

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Code No: R05312401

Set No. 2

III B.Tech I Semester Regular Examinations, November 2007 DESIGN OF MACHINE ELEMENTS (Automobile Engineering) Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks ⋆⋆⋆⋆⋆ 1. Enumerate the factors to be considered while selecting the materials for machine parts. Recommend suitable materials for each of the following components : (a) Crankshaft (b) Body of electric motor (c) Worm gear (d) Piston for motor car engine (e) Lathe bed (f) Bearing bush [16]

2. (a) Explain the Modiﬁed Goodman’s line theory for designing the components subjected to fatigue loads (b) A thin wall cylindrical pressure vessel of mean diameter of 60 cm is subjected to internal pressure varying from 0 to 40 MPa. Find the required thickness of the pressure vessel based on yield point of 400 MPa, endurance limit of 22 Mpa, and a factor of safety of 3. Use Soderberg criterion of failure. [6+10] 3. (a) What do you mean by eﬃciency of riveted joint? (b) A locomotive boiler of 1.8 m internal diameter is required to generate steam at 1.4 MPa gauge. Calculate the thickness of the shell plate and design the triple riveted longitudinal double butt strap joint with unequal straps. Use the following data: σt = 77 MPa, τ = 60 MPa and σc = 135 MPa. Eﬃciency of triple-riveted longitudinal butt joint is 84%. [4+12] 4. (a) What is the function of transmission shaft? (b) A machinery shaft is subjected to torsion only. The bearings are 2.40 metre apart. The shaft transmits 187.5 kW at 200 rev/min. Allow a shear stress of 42 MPa after an allowance for keyways. i. Determine the shaft diameter for steady loading ii. Determine the shaft diameter if the load is suddenly applied with minor shocks. [2+14] 5. (a) Under What circumstances, concentric springs are preferred?

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Code No: R05312401

Set No. 2

(b) A rail carriage weighing 200kN and running at 5 km/hour is brought to rest by four buﬀer springs of close coiled helical type during connection with another carriage which is already at rest. The mean coil diameter is 5 times the wire diameter. The deﬂection of each spring is 220 mm, to bring the carriage to rest. Safe shear stress for the spring material is 400 N/mm2 . Calculate the maximum load on the spring, diameter of wire and coil, number of turns and free length of spring. Assume the ends of spring are squared and ground. Take G= 0.8×104 N/mm2 . [2+14] 6. (a) What are the commonly used materials for sliding contact bearings? (b) A ball bearing subjected to a radial load of 5kN is expected to have a life of 8000 hours at 1450 r.p.m with a reliability of 99%. Calculate the dynamic load capacity of the bearing so that it can be selected from the manufacturer?s catalogue based on a reliability of 90%. [2+14] 7. Design a connecting rod of I cross section for an automobile diesel engine of the following speciﬁcations. Diameter of cylinder=100mm Stroke length =125mm Maximum combustion pressure =2.8MPa Maximum engine speed=2000rpm Weight of the reciprocating parts =1.1kg Length of connecting rod between centers=31.5cm Assume an allowable crushing stress =3000kg/cm2 .

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8. Design a Cast iron piston for a single acting four stroke engine for the following speciﬁcations. Cylinder bore = 100mm, Stroke = 120mm, Maximum gas pressure = 5N/mm2 , Break mean eﬀective pressure = 0.65N/mm2 , Fuel consumption = 0.227kg/kW/hr, Speed =2200 rev/min, Assume suitable data. [16] ⋆⋆⋆⋆⋆

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Code No: R05312401

Set No. 3

III B.Tech I Semester Regular Examinations, November 2007 DESIGN OF MACHINE ELEMENTS (Automobile Engineering) Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks ⋆⋆⋆⋆⋆ 1. (a) What are the various factors inﬂuencing the factor of safety? Explain. (b) The piston of a reciprocating compressor has a diameter of 60 mm. The maximum pressure on the piston face is 1.25 MN/ m2 . Assuming that the gudgeon pin passing through the small end of the connecting rod can be safely loaded in shear upto 10 MN/m2 , calculate the minimum diameter of the gudgeon pin. [6+10] 2. (a) How will you reduce stress concentration in shaft with keyway? (b) A torsion bar spring has a solid round 20 mm diameter section which blends smoothly at each end with a larger splined section. It is subjected to a completely reversed nominal torsional stress of 210 MN/m2 . Stress concentration is negligible, and the surfaces are machined. Estimate the fatigue life corresponding to each of the following materials: i. steel= 250 HB, ii. Cast iron Su = 350 MN/m2 . 3. (a) What forms of rivet heads are used in boiler construction? (b) A triple riveted lap joint is to be made between 6 mm plates. If the safe working stresses are ft = 84 MPa, fs = 60 MPa and fc = 120 MPa, calculate the rivet diameter, rivet pitch and distance between rows of rivets for the joint. Zig-zag riveting is to be used. State how the joint will fail. [4+12] 4. (a) What is a line shaft? Give examples. (b) A centrifugal circulating pump for a stream turbine condenser is to be directly connected to a motor through a short shaft and a pair of ﬂexible couplings. The pump delivers 20 m3 per minute at 865 rev/min against a dynamic head of 7.5 metres. The pump eﬃciency is 80 percent. i. Determine the power of the motor required ii. Assuming hot rolled C-40 steel, determine diameter of Shaft. [4+12] [4+12]

5. A diesel engine weighs 800kN and is mounted on 16 springs in order to protect the building from vibrations. The section of the spring wire is rectangular with side ratio 1.8. One spring has four eﬀective coils and the spring index is 6. Determine: (a) section of the spring so that long side is parallel to the axis of the spring (b) Deﬂection under load when engine is stationary. 1 of 2

Code No: R05312401 (c) Maximum coil diameter.

Set No. 3

(d) Shear stress induced if shorter side is parallel to the spring axis. Permissible shear stress in spring wire material is 300 N/mm2 and modulus of rigidity is 0.8×105 N/mm2 . [16] 6. (a) Diﬀerentiate between rated and average life of anti-friction bearings. (b) A 6203 single row deep groove ball bearing has a basic static load rating of 4500N, and basic dynamic load rating of 7350N. A radial load of 1600 N, and an axial load of 1400N are acting on the bearing. Calculate the rated life of the bearing. [4+12] 7. Design a connecting rod for an I.C engine from the following data: Piston diameter = 125mm Stroke=150mm Length of connecting rod=300mm Maximum gas pressure at 5% of stroke =5N/mm2 Speed of engine =1200rpm Mass of reciprocating parts =2kg Factor of safety=5 Material steel =35 Ni Cr 60.

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8. Design a Cast iron piston for a single acting four stroke engine for the following speciﬁcations. Cylinder bore = 100mm, Stroke = 120mm, Maximum gas pressure = 5N/mm2 , Break mean eﬀective pressure = 0.65N/mm2 , Fuel consumption = 0.227kg/kW/hr, Speed =2200 rev/min, Assume suitable data. [16] ⋆⋆⋆⋆⋆

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Code No: R05312401

Set No. 4

III B.Tech I Semester Regular Examinations, November 2007 DESIGN OF MACHINE ELEMENTS (Automobile Engineering) Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks ⋆⋆⋆⋆⋆ 1. (a) What is meant by bilateral tolerance? (b) Deﬁne the terms: i. clearance ﬁt, ii. transition ﬁt, and iii. interference ﬁt.

[4+12]

2. (a) Diﬀerentiate between theoretical stress concentration factor and fatigue stress concentration factor. (b) A simply supported shaft of 50 mm diameter and 0.5 long is subjected at its mid-section, a load that varies cyclically from 2P to 4P. Determine the value of P from the following: Yield strength = 450MPa Endurance limit = 350MPa Factor of safety = 2 Size correction factor = 0.85 Surface correction factor = 0.90 [4+12] 3. (a) Develop the expression for the induced maximum shear stress in parallel ﬁllet weld. (b) A circular cantilever beam of 50 mm diameter and 250 mm length is to be welded to a side member. The maximum load of 8 kN is applied repeatedly. Determine the size of the weld required for 3,00,0000 cycles. Assume that the shear load is distributed over the entire weld. [6+10] 4. (a) What is spindle? Give examples. (b) A machinery shaft supported on a bearing 2.4 metre apart is to transmit 187.5 kW at 200 rev/min. It is subjected to a bending load of 5000 N located at a distance of 0.66 metre from one bearing. Safe stress in shear is 42 MPa and in bending 84 MPa. i. Determine the shaft diameter for steady loading ii. Determine the shaft diameter if the transverse load is steady and the torsional load is suddenly applied. [4+12] 5. (a) Give in detail; the design procedure for the design of a leaf spring of an automobile. Indicate, how the unequalised stresses produced in full length and graduated leaves at maximum load are counted in design? 1 of 2

Code No: R05312401

Set No. 4

(b) A close coiled helical compression springs of 12 active coils has a spring stiﬀness of P0 . It is cut in to two springs having 5 and 7 turns. Determine spring stiﬀ nesses of resulting springs. [10+6] 6. (a) Explain the principle of hydrodynamic lubrication. (b) Select a single row deep groove ball bearing for a radial load of 4000N and an axial load of 5000 N, operating at a speed of 1600r.p.m for an average life of 5 years at 10 hours per day. Assume uniform and steady load. [6+10] 7. A crank shaft of the center- crank type is to be designed for a diesel engine developing 7.5kW on brake at 1200r.p.m. The crank shaft is of the forged type and has to carry two ﬂy wheels of 500N each on either side of the main bearing. The plane of rotation of each ﬂy wheel is 100mm from the center line of adjacent main bearing. The maximum load on connecting rod is 35kN. The length of stroke of piston is 160mm and the length of connecting rod 320mm. Maximum torque will be experienced in the crank shaft when the crank turns 300 from the inner dead center position. The maximum permissible stress in crank pin, web and shaft should not exceed 60N/mm2 , the safe limit for the bearing stress for the crank pin and the main bearings is 800N/mm2 . Design the crank shaft. [16] 8. The following particulars relate to a slow speed oil engine working on 4-Stroke cycle : Indicated power = 15kW RPM =300 Maximum explosion pressure = 2.1MN/m2 Mean eﬀective Pressure = 0.56MN/m2 Design (a) The suitable trunk piston and piston rings (b) The Piston and give a neat dimensioned sketch of the piston assembly, incorporating all necessary details, clearly indicating the materials used for each part. [16] ⋆⋆⋆⋆⋆

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