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1 What are the various phases of design process? i. Recognition of need. ii. Definition of problem iii. Synthesis iv. Analysis and optimization v. Evaluation vi. Presentation Define: Factor of safety The ratio between maximum stresses to working stress is known as factor of safety.Factor of safety = Maximum stress / Working stress The dimensions of the mating parts, according to basic hole system, are given as follows: Hole: 25.00 mm Shaft: 24.97 mm 25.02 mm 24.95 mm Find the hole tolerance, shaft tolerance and allowance

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1 A hollow shaft of 40 mm outer diameter and 25 mm inner diameter is subjected to a twisting moment of 120 N-m, simultaneously, it is subjected to an axial thrust of 10 kN and a bending moment of 80 N-m. Calculate the maximum compressive and shear stresses.

9. We know that for reversed axial loading. the load correction factor (Ka) is 0.S. F.Undercutting the shoulder parts.2 Give some methods of reducing stress concentration. Solution. 2 5 . i.Use of multiple holes instead of single hole iv.Avoiding sharp corners. = 2 The piston rod is subjected to reversed axial loading. The surface of the rod is ground and the surface finish factor is 0.Providing fillets. The load is predictable and the factor of safety is2. Given: Ksur = 0. iii.9. Determine the design stress for a piston rod where the load is completely reversed. There is no stress concentration.8. ii.

redesign the pa rt in the light of test result.Soderberg relation. such as measures of the effects of loading and /or environment of the part. the following factors should be considered. 5 2 Define stress concentration and stress concentration factor. (vi)Construct a prototype. physics and chemical properties and their economy .The selection involves a comparison of the anticipated effects of loading andenvironment expressed in terms of the appropriate criteria of behavior. test. and correspon ding limiting characteristics or design criteria of the material for the particular condition of loading the choice of design criteria may be influenced by the type of material. (iv)Select materials on the basis of their mechanical. (iii)Established and evaluate criteria of behavior related to the expected modes of failure.What are the various factors to be considered for failure and wear aspects of machine co mponents? Ans: To prevent failure of critical parts. Modified Goodman relation and 3. and factor of safety = 2. tolerances & surface finish etc. (i) Develop a suitable shape. evaluate the performance and if necessary. Gerber relation 2. Determine the value of minimum ultimate strength according to 1. Endurance strength = 0.5 Ultimate strength. (v) Select the final dimensions. . This may require a kinematic analysis of the system (ii) Anticipate probable loads and environmental effect to be encountered. Take yield strength = 0. Stress concentration factor is the ratio of maximum stress at critical section to the nominal stress 2 A machine component is subjected to a flexural stress which fluctuates between +300 10 2 2 MN/m and -150 MN/m .55 Ultimate strength. Stress concentration is the increase in local stresses at points of rapid change in cross section or discontinuities.

σe=0. 12 . = 2 3 A double riveted lap joint is made between 15 mm thick plate. σ2=-150 MN/m2. find the minimum force per pitch which will rupture the joint.Solution. The rivet diameter and pitch are 25 mm and 75 mm respectively. find out the actual stresses developed in the plates and the rivets.5 σu. σy=0. 320 MPa in shear and 640 MPa in crushing. Given: σ1=300 MN/m2. If the ultimate stresses are 400 MPa in tension. F. If the above joint is subjected to a load such that the factor of safety is 4.55 σu.S.

The parts can be rigidly connected c. They are highly reliable in operation b. They are convenient to assemble & disassemble c. Used for transmitting power Advantage a. A wide range of screws can be used for various operating conditions 4 . For readily connecting & disconnecting machine parts without damage b.3 Give the application and advantages of screwed fasteners Application a.

Given data: Pi= 1.26 mm Thickness of rivet plate: t1 = PiD/2Sdη = 16.525 mm.d. Sys = 140 MPa Thickness of plate: t = PD/2Sdt = 14. They are relatively cheap to produce Design a boiler joint (longitudinal & circumferential) to handle a pressure 1.5√t = 26. Tensile stress = Compressive stress = 50MPa. The material used is carbon steel for which the following allowable stresses may b e used. Therefore. Solution Given data: P = 30 KN Sdt =50 N/mm2 Sdc = 90 N/mm2 Sds = 35 N/mm2 1) Diameter of rod (d): .1 mm Margin m = 1.8 MPa D = 1.3 m = 1300 mm Selecting Plate Material: SAE 2010 Syt = 246 MPa.9 mm 8 4 Design a cotter joint to support a load varying from 30 KN in compression to 30 KN in te 12 nsion.54 = 93. As pitch is less than Pmin.54mm Check the pitch: Pmin = 2.3 mm Circumferential Joint П/4D2Pi = (П/4d2Sds)N N = 90 Pitch = П(D+2t)/N = 96.77 mm (η = 85% for triple row) d= 6√t or 7√t d = 6. no. Sys = 154 MPa Rivet Material: SAE 1010 Syt = 218 MPa. of rivets per row is 90/2 = 45. Shear stress = 35MPa & Crushing stress = 90 MPa.5d = 66.8 MPa with an internal diameter of 1.61 mm P = {(П/4d2 (2n2 +n1) Sds)/ tSdt} + d = 201. Pitch = 2 x 46. Solution. arrange the rivets in two rows.5d = 39.3 m. The load applied is statically.

Since.t .Sdc d4=75mm 6) Thickness of socket collar(t1): Considering failure of socket end in shear. P = 2ad2Sds. 11) Dimension e e = 1. P = П/4 d4 Sdt d=28mm 2) Diameter of spigot (d2) & thickness of cotter(t): Considering failure of spigot in tension across weakest section. t= d2/4 = 8. P = (П/4(d4)‐(d2t)).Sds b = 43mm 5) Diameter of socket collar (d4): Considering failure socket collar of in crushing. . P = П d2 t2 Sds t2= 8 mm 9) Length of cotter(L): L = 4d = 112 mm 10) Distance from the end of slot to the end of rod (a): Considering rod end in shear. Since. P = (d4 – d2)t .Sds t1 = 12 mm 7) Diameter of spigot collar(d3): Considering failure of spigot collar in crushing.b. P = {(П /4(d32)‐ (d22) }Sdc d3 = 45 mm 8) Thickness of spigot collar(t2): Considering failure of spigot collar in shearing. P = {( П/4(d12)‐(d22)‐ (d1‐ d2) }.Sdt d2 = 34 mm. cotter is in double shear P = 2. socket end is in double shear. Since.Considering failure of rod in tension.Sdt d1 = 50 mm 4) Width of cotter(b): Considering failure of cotter in shear.5 mm 3) Outside diameter of socket(d1): Considering failure of socket in tension across the slot. rod end is in double shear.2 d e =34 mm. P = 2(d4‐d2)t1. a = 11 mm.

414hl1Sds l1 = 36. The maximum working ten sile & shear stresses are 75 N/mm2 & 55 N/mm2 respectively. ii.5 mm Load on plate P = Area x Stress =75000N Length of transverse weld = l2 = 100‐12.5 = 87.5 mm Load carried by joint P = 0. ii. 2 List any five advantage of welded joints over riveted joints 5 .h.Sdt +1.l2. Sds = 55 N/mm2 l1 + l2 = 12. Sdt = 75 N/mm2.77 mm State the two types of eccentric welded connections.4 A plate of 100 mm wide & 10 mm thick is welded to another plate by a single transverse fillet weld & a double parallel fillet welds as shown in figure. Welded connections subjected to moment in a plane normal to the plane of the weld. t =10 mm.5 mm. Welded connections subjected to moment in a plane of the weld. Find the length of respective welds. Assume overall length equal to 12. i. 5 Ans: Given data: w = 100 mm.707.

5 kW at 180 r. If the allowable shear stress in the material is 60 MPa.p.m. find the suitable diameter for the shaft.5 a)What are the basic assumption made in torsion equation? 2 b) A shaft is transmitting 97. The shaft is not to twist than 10 in a length of 3 meters. Take C = 80 GPa 8 .

5 mm respectively.5 GPa 12 . What are the types of Flexible coupling? i. and BC and CD are solid. if the maximum shear stress in the hollow portion is 47. Universal.5 m consist of three lengths different section as follows: AB is hollow having outside and inside diameter of 100 mm and 62. Oldham’s.c). ii. Pushed pin type coupling.5 mm. 2 (OR) 5 A steel shaft ABCD having a total length of 3. If the angle of twist is the same for each section.5 MPa shear modulus. C = 82. BC has a diameter of 100 mm and CD has a diameter of 87. determine the length of each section. Find the value of the applied torque and the total angle of twist. iii.

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