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GHARDA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering Question Bank Subject: Machine Design-I Year-2013-14, SEM: EVEN MODULE

I: MECHANICAL ENGINEERING DESIGN 1. 2. 3. 4. 5. 6. 7. 8. 9. Explain Theories of failure of machine components. Explain ergonomic and aesthetic considerations in design. Write short note on preferred series and numbers. What are the design considerations in castings and forgings? Define factor of safety. On which factors its selection depends? Suggest various values for different types of loads and materials. Write on Mechanical Properties of materials and their uses in design. What are the different modes of failure of mechanical components? Write on factors affecting selection of materials. Recommend suitable value of factor of safety, with justification for the following applications: Lathe bed Crane hook Crank shaft Lead screw Heavy Duty Gear valve spring V Belt Gasket Class: T.E.Mechanical

10. Types of fit 11. State the maximum shear stress theory of failure. Show that Ssy=0.5Syt. How is this relation as per the octahedral shear stress theory? 12. What are the various steps in design process? 13. State the various strengths of a material. 14. What is permissible stress or design stress? State the various factors to be considered, while deciding permissible stress. 15. Write short note on stress strain diagram. 16. Write short note on standardization. 17. What are the modes of failure in mechanical engineering components?

GHARDA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering Question Bank Subject: Machine Design-I Class: T.E.Mechanical Year-2013-14, SEM: EVEN

MODULE II: DESIGN AGAINST STATIC LOADS 1. Define static and fatigue stress concentration factors and establish relationship between them. 2. A bracket is subjected to a vertical force of 10 KN is shown in figure 1. It is fastened to a vertical plate by means of four identical bolts. Determine the size of bolts using maximum shear stress theory if maximum permissible shear stress in any bolt is limited to 50 MPa. 3. A steel plate 80 mm wide and 10 mm thick is joined to another steel plate by means of a single transverse and double parallel fillet welds as shown in fig.2.The strength of welded joint should be equal to the strength of the plates to be joined. The permissible tensile and shear stresses for the weld material and the plates are 100 and 70 MPa respectively. Find the length of each parallel fillet weld assuming tensile force passes through centre of gravity of three welds. 4. Design screw and nut for screw press for load of 120 KN and 400 mm height adjustment. 5. A screw press is to be designed to exert an axial force of 30 KN. a. Select suitable materials and design the nut and screw. Assume the height of the screw press to be 250 mm. b. Design the horizontal section of the frame if the axis of the screw is at a distance of 250 mm form the inner edge of the frame. Give the reasons for the selection of material of the frame. 6. Design socket and spigot type of cotter joint to transmit reversible load of 80 KN. Select suitable materials for the various parts. 7. Calculate the size of weld required for an eccentrically loaded weld shown in fig 3.The allowable stress in the weld as 75 MPa. 8. What is stress concentration? What are the methods to reduce it? 9. Find the diameter of the bolt of the arrangement shown in figure 4.Assume for the material of the bolt Sy=350 MPa and a factor of safety =3.5

GHARDA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering Question Bank Subject: Machine Design-I Class: T.E.Mechanical Year-2013-14, SEM: EVEN

10. Design a turnbuckle to connect two tie rods. The pull in tie rod is 50 KN. Select suitable materials and designs the turnbuckle. 11. Find the size of fillet weld (h) for cantilever circular bar of 50 mm diameter (to be welded to plate) subjected to bending moment of 400 KNmm.Take allowable stress for weld material as 60 MPa. 12. Screw press is subjected to load of 80 KN,height of screw is 500 mm.Frame overhang is 400 mm.Design: i. Screw and nut ii. Horizontal section of frame. 13.A knuckle joint is to transmit a reversible load of 25 KN. Select suitable materials for various parts. Discuss the failure modes of components select permissible stresses giving reasons and design the joint. 14. How to estimate initial tension in a bolt to give a leak proof joint. Explain. 15. A bracket carrying a load of 22.5 KN is to be welded on to a vertical plate by 3 fillet welds as shown in figure 4.Calculate the size of weld if permissible shear stress in the weld is 90 MPa. 16. A bracket is bolted to a vertical wall by means of four bolts as shown in figure 5.Which one of the bolts is most severely loaded?Why?What are the stresses developed in the bolt? 17. A screw press is to be designed to exert an axial force of 30 KN. a. Select suitable materials and design the nut and screw. Assume the height of the screw press to be 300 mm. b. Design the horizontal section of the frame if the axis of the screw is at a distance of 250 mm form the inner edge of the frame. Give the reasons for the selection of material of the frame.

GHARDA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering Question Bank Subject: Machine Design-I Class: T.E.Mechanical Year-2013-14, SEM: EVEN 18. A knuckle joint is subjected to axial load which changes from zero to 60 KN tensile. a. Select appropriate material and factor of safety with justification. What types of manufacturing processes will be utilized? Decide design stresses. b. Determine all dimensions for various failures. Indicate by clear sketches the area involved in each failure. c. Draw neat dimensional sketch. 19. Machine screw press is subjected to axial force 40 KN.Overhang of its horizontal of frame is 400 mm and height of screw is 500 mm. a. Select suitable material and stresses for screw and nut and frame. b. Design screw and nut c. Check screw for buckling failure d. Determine dimensions of cross section of horizontal member of frame. 20. In an eccentrically loaded bolted joint, the eccentric load is perpendicular to bolt axes. What types of stresses are developed in bolts? Discuss. 21. What do you understand by combined stresses? 22. What are the basic modes of failure in mechanical engineering components? 23. Establish the fact that the shear stress in the fillet welds shall be considered as shear stress on the throat for any direction of loading. 24. Why square threads are are preferable to V-threads for power transmission? And how does the helix angle influence on the efficiency of square threaded screw. 25. Two tie rods are connected by a sleeve using cotters. They are subjected to an axial pull to 50 KN.Design the joint using following design stresses. For rods and cotters (C30): [t]=60 MPa, [c]=70 MPa,[]=30 MPa For sleeve (cast-steel): [t]=65 MPa, [c] =100 MPa,[]=45 MPa 26.Find the diameter of the rivet in arrangement of the joint shown in figure 6. Maximum shear stress in the rivet is limited to 65 MPa. The maximum load carried by the joint is 109 KN.Assume that all the rivets are of the same size.

GHARDA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering Question Bank Subject: Machine Design-I Class: T.E.Mechanical Year-2013-14, SEM: EVEN 27. A toggle jack is to be designed for lifting a load of 4 KN.When the jack is in the top position, the distance between the centre links of the nuts is 50 mm and in the bottom position, the distance is 210 mm.The eight links of the jack are symmetrical and 110 mm long. The link pins in the base are set 30 mm apart. The links, screw and pins are made from the mild steel for which the permissible stresses are 100 MPa in tension and 50 MPa in shear. The bearing pressure on the pins is limited to 20 MPa. Assume the pitch of the square threads as 6 mm and coefficient of friction between threads as 0.2. 28. A Steel plate subjected to a force of 10 KN and fixed to another plate by means of three identical bolts is shown in figure 7.The bolts are made from C-40 material. Factor of safety is 3.Specify the size of bolts. 29. State the advantages and disadvantages of square threads over trapezoidal threads. 30. How to estimate initial tension in bolt to give leak proof joint?

GHARDA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering Question Bank Subject: Machine Design-I Class: T.E.Mechanical Year-2013-14, SEM: EVEN MODULE III: DESIGN AGAINST FLUCTUATING LOADS 1. A machine component is subjected to fluctuating stress that varies from 40 to 100 MPa.The corrected endurance limit for the component is 270 MPa.The ultimate tensile strength and yield strength at the material are 600 and 450 MPa respectively. Find the factor of safety using i. Soderberg line ii. Goodman line iii. Gerber Theory iv. Also find factor of safety against static failure for maximum stress. 2. Discuss in detail on Goodman design criteria. 3. Write short notes on Soderberg line. Why it is said that Soderberg line is a conservative basis of design. 4. Explain mechanism of fatigue failure. 5. A cold drawn steel bar is to withstand a tensile preload of 36.3 KN and a fluctuating tensile load varying from 0 to 72.6 KN .The bar has a geometric stress concentration of 2.2 corresponding to a fillet whose radius is 4.75 mm.Determine the size of bar for an infinite life and a factor of safety of 2.The material properties are Syt=588 MPa,Sut=700 MPa,Ksurface=0.73,Kload=0.85,notch sensitivity q=0.64 6. Discuss on various Fatigue cycles and factors affecting Endurance Limit. 7. A circular cross section bar is subjected to tensile force varying from 150 KN to 450 KN.It is to be manufactured by Carbon Steel-C 35.Determine size of bar as per Soderberg equation, with n=1.75. 8. A bolted assembly is subjected to an external force which varies from 0 to 10 KN.The combined stiffness of the parts held together is three times the stiffness of the bolt. The bolt is so initially tightened that at 50 % overload condition, the parts held together by the bolt are just about to separate. The bolt is machined from plain carbon steel 50C4 (Sut=660 MPa and Syt=460 MPa).The fatigue stress concentration factor is 2.5 and expected reliability is 95 %.The factor of safety is 2.Determine the size of bolts with coarse threads.

GHARDA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering Question Bank Subject: Machine Design-I Class: T.E.Mechanical Year-2013-14, SEM: EVEN MODULE IV: DESIGN OF SHAFT, KEYS AND COUPLINGS 1. A solid shaft supported on bearings C & D,1000 mm apart between the centres.A pulley having diameter 1250 mm is mounted at 250 mm to the left of bearing C and a spur gear having 750 mm pitch circle diameter is mounted 350 mm to the right of bearing D.The gear is driven by a pinion located horizontally behind while pulley transmits power to another pulley of same diameter located vertically below.The coefficient of friction between pulley and belt is 0.3.The shaft rotates in clockwise direction looking from right.The pulley and gear weigh 2700 N and 900 N respectively. Design the shaft, if the power transmitted is 20 KW at 150 rpm.Assume the load suddenly applied with minor shock. 2. A solid shaft is transmitting 40 KW at 960 rpm is supported on two bearings,1 m apart and has two spur gears keyed on it. The pinion is having 200 mm PCD and is located 150 mm to the left of RH bearing and tangential force acts horizontally on it. The gear is having 500 mm PCD and is located 250 mm to the right of LH bearing, and the tangential force acts vertically downwards on it. Select suitable material and find diameter from maximum shear stress theory and normal stress theory. 3. State various types of keys used for shafts for torque transmission and describe their special features. 4. A shaft transmitting 30 KW at 400 rpm is supported in two bearings 650 mm apart and carries two gears. A 25 teeth involute,6 mm module gear is located 150 mm to the right of the LH bearing and delivers power to the left of RH bearing and receives power from a gear vertically above. The shaft rotates clockwise when viewed from right. Select suitable material for the shaft and design the shaft.

GHARDA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering Question Bank Subject: Machine Design-I Class: T.E.Mechanical Year-2013-14, SEM: EVEN 5. A shaft is housed in the bearing 2.2 m apart. It carries a pulley of diameter 350 mm at 200 mm to the right of LH bearing. It also carries another pulley of 550 mm diameter at a distance of 1000 mm to the left of RH bearing.350 mm pulley receives 25 KW power from a motor kept below it with the help of flat belt drive. The coefficient of friction and angle of contact for both the pulleys are 0.28 and 160 .Design the solid shaft. Assume the weights of both pulleys are 1.2 KN each and shaft is made of C-45.The assembly rotates with 440 rpm in clockwise direction when direction when viewed from left to right. 6. Explain the effect of keyway on shaft strength. Give equation for Shaft Strength Factor. 7. Design flange coupling (Protected Type) to transmit 60 KW at 1440 rpm.Select suitable materials and appropriate factors of safety with justification. 8. Compare weight, strength and stiffness of a hollw shaft of the same external diameter as that of solid shaft. The inside diameter of hollow shaft being half the external diameter. Both the shafts have same material and length. 9. A hollow shaft and solid shaft have same cross sectional area. Which one will be stronger to resist bending or torsion? Why? 10. A shaft is supported in bearings A and B 1000 mm apart between centres.An involute spur gear having 400 mm pitch circle diameters located 300 mm to the right of left hand bearing A and a 600 mm diameter pulley is mounted 350 mm to the left of right hand bearing B.The gear is driven by a pinion located vertically above, while the pulley transmits power to a pulley located vertically below.The belts have an angle of lap of 180 and coefficient of friction between the belt and the pulley is 0.25.The pulley also serves as the flywheel and weights 2500 N.Design the shaft, if the power transmitted is 30 KW at 400 rpm.The shaft rotates clockwise when viewed from right. Use octahedral shear stress theory. 11.Design a flexible type bushed pin coupling for the shaft transmitting 20 KW at 1440 rpm.Assume suitable material and stresses for various parts.

GHARDA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering Question Bank Subject: Machine Design-I Class: T.E.Mechanical Year-2013-14, SEM: EVEN 12. Why hollow shaft is beneficial over solid shaft? 13. A shaft is supported in bearing at A and B apart carries a 180 mm diameter spur gear (20 pressure angle) at C at a distance 220 mm from A toward B.Two pulleys D and E of equal diameter of 300 mm are mounted on it at a distance of 650 mm and 1050 mm from bearing A.The gear receives 40 KW power from a pinion vertically above it and delivers 20 KW power through pulley D to one machine and rest of the power through pulley E to another machine. The belt tensions at D are parallel but inclined at 30 to the vertical in the downward direction towards left. The tensions at E are also parallel but horizontal towards right. The ratio of belt tensions at D and E is 2.5.The mass of pulleys D and E is 25 kg each. The shaft rotates at 800 rpm.Design the shaft taking []=40 MPa. 14. Split muff coupling is subjected to 20 KW at 1440 rpm. a. Draw a neat sketch of coupling b. Select materials for various components and decide allowable stresses. c. Design shaft d. Design key and sleeve e. Design studs and check for feasibility 15. What are the causes of failure of shaft? 16. An overhang shaft carrying a pulley and a gear is supported at two bearings 1 m apart. The shaft transmits 20 KW at 15 rpm.The gear is located at 350 mm to right of RH bearing and tangential force on gear acts vertically upwards (Radial force on gear may be neglected).PCD of gear is 750 mm.The pulley is located at 250 mm to left of LH bearing and delivers power through a flat belt vertically below.The ratio of tensions is 2.5.Diameter of pulley is 1250 mm.The gear and pulley weigh 900 N and 2700 N respectively. The allowable shear stress for the material of shaft is 65 MPa.Shock and fatigue factors for bending and torsion is 2.0 and 1.5 respectively. Recommend suitable diameter of shaft.

GHARDA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering Question Bank Subject: Machine Design-I Class: T.E.Mechanical Year-2013-14, SEM: EVEN 17. The input shaft of a machine is supported in bearings at A and D.It receives 40 KW power through a flat belt pulley 400 mm diameter located at B from a pulley located vertically below.The angle of lap is 22.5 and the coefficient of friction between the belt and the pulley is 0.25.The shaft rotates at 400 rpm in the anticlockwise direction when viewed from D and delivers power through a pinion having 20 teeth and 6 mm module having pressure angle of 20 ,located at C.It transmits power to a gear located horizontally in front. The material for shaft is IS-C-45 and factor of safety is 4.AB=250 mm, BC=CD=200 mm. 18. Explain four important types of keys with their specific uses. 19. Design a flexible type Bush-Pin coupling for the shaft transmitting 30 KW power at 960 rpm.Assume suitable material and design stresses for various parts. 20. Differenciate between shaft and axle. 21. Explain various types of couplings used in practice.

GHARDA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering Question Bank Subject: Machine Design-I Class: T.E.Mechanical Year-2013-14, SEM: EVEN MODULE V: DESIGN OF SPRINGS 1. A Semi-elliptic leaf spring used for suspension of truck has 12 leaves, two of which are extra full-length leaves. The centre-to-centre distance between the spring eyes is 1.2 m and the central band is 80 mm.The leaves are made of alloy steel having yield strength 1200 MPa and modulus of elasticity 2105 N/mm2 and the factor of safety is 3.The spring is to be designed for a maximum load of 10 KN.The leaves are pre-stressed so as to equalize stresses in all leaves.Determine the width and thickness of leaves if the ratio of total depth to the width of spring is 2.5.Also find the deflection at the end of the spring. 2. Design a closed coiled helical compression spring used for a boiler safety valve which is required to blow steam at the pressure of 1.5 N/mm2.The diameter at valve is 50 mm.The initial compression of the spring is 40 mm and the lift is limited to 20 mm.The number of cycles of load are expected to be about 10 5.The material of the spring is chrome vanadium steel for which the strength values are: Su= 2000/dw0.17,Sys=1200/ dw0.17 and G=80000 N/mm2 Use static approach. Also check for solid stress. 3. Write a note on Wahl stress factor for coil spring.

GHARDA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering Question Bank Subject: Machine Design-I Class: T.E.Mechanical Year-2013-14, SEM: EVEN 4. A semielliptical laminated leaf spring has to carry a central load of 4000 N and consists of six leaves, two of the leaves extending to full length. The spring is having 900 mm length and central band is 80 mm wide. Select suitable material and find (Take b/t =4):i. Thickness (t) and width (b) of leaves ii. Camber of spring iii. Length of leaves iv. Radius of leaves in free condition. 5. A helical spring is subjected to load varying from 500 N to 1100 N having spring index of 6, free length of the spring is to be lie between 100 mm to 150 mm.The maximum compression under the variation of load is 3 cm.Assume stresses for spring material and G= 0.8105 N/mm2 .Design the spring and find out energy stored in the spring. 6. The leaf spring has 12 numbers of leaves, two of which are full length of leaves. The spring supports are 1.1 m apart and the central band is 90 mm wide. The central load is to be taken 5.5 KN with the permissible stress of 300 N/mm2.Determine: i. Thickness and width of the steel leaves ii. Deflection of spring Take the ratio of the total depth to the width of the springs as 3. 7. A helical compression spring is subjected to varying load, maximum upto 1.2 KN.Design spring with static approach (Average service), for a deflection of 40 mm.Take ultimate tensile stress for spring material as 1600 N/mm 2.Decide appropriate allowable shear stress.

GHARDA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering Question Bank Subject: Machine Design-I Class: T.E.Mechanical Year-2013-14, SEM: EVEN 8. A single plate dry clutch transmits 20 KW at 2000 rpm with both sides of the plate being effective.The maximum wear on each side of the plate is limited to 1 mm.Under these conditions, the capacity of the clutch should not fall by more than 10 %.The necessary axial pressure on friction plate is obtained by means of six helical compression springs. Design the springs. Assume the following data: outer radius of clutch plate 120 mm, inner radius of clutch plate 80 mm, coefficient of friction 0.35.Torque transmitted by a clutch is given by T=nwRm. For the material of the spring Su= 2000/Dw0.17,Sys=1200/ Dw0.17 and G=80000 N/mm2 9. A helical compression spring is subjected to load varying from zero to maximum of 9 KN, with corresponding deflection of 90 mm.Considering average service and spring steel having ultimate tensile stress, u= 2000/Dw0.17 N/mm2 ,where d is the diameter of spring wire in mm and G=80000 N/mm2 . Determine: i. Wire diameter (d) and coil diameter (D) ii. Total no. of coils iii. Free length, pitch and helix angle iv. Check for solid stresses 10. Explain prestressing, relaxation and surging in spring. 11. What is nipping in the leaf spring? Discuss its role. List the materials commonly used for the manufacture of the leaf spring.

GHARDA INSTITUTE OF TECHNOLOGY Department of Mechanical Engineering Question Bank Subject: Machine Design-I Class: T.E.Mechanical Year-2013-14, SEM: EVEN 12. A helical compression spring is subjected to a force of 500 N with corresponding deflection of 20 mm.The spring index is 6.The spring material has UTS of 1000 N/mm2.The permissible shear stress for the spring wire is 50 % of UTS. Modulus of elasticity is 8104 N/mm2 .Design the spring and determine: i. Wire diameter ii. Mean coil diameter iii. No. of active turns iv. Free length v. Pitch of the coils 13. Explain various streeses in spring neat sketches. 14. Write down various applications of spring.