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III B.Tech. I Semester Supplementary Examinations, June/July - 2014

Design of Machine Members-I

(Mechanical Engineering)

Time: 3 Hours Max Marks: 75

Answer any FIVE Questions

All Questions carry equal marks

*****

om

1. (a) A weight of 1400 N is dropped on to a collar at the lower end of a vertical steel

shaft of 3m long and 25 mm. diameter, calculate the height of drop if the maximum

instantaneous stress produced is not to exceed 120 MPa. Take E = 2.1 x 105 MPa.

.c

(b)Explain the influence of stress raiser on impact strength

(c)Explain the term factor of safety.

us

2. A steel member of circular cross section is subjected to a torsional stress that varies

from 0 to 35 MPa and at the same time it is subjected to an axial stress that varies

pl

from 14 MPa to 28 MP(a)Neglecting stress concentration and column effect

determine

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(i) the maximum equivalent shear stress.

(ii) the design factor of safety based upon yield in shear. The material has an

si

endurance limit = 260 MPa and a yield strength = 480 MP(a)The size factor may be

taken as UNITY and the surface has a mirror polish

er

3. (a) What is the difference between caulking and fullering? Explain with neat

iv

diagrams?

un

(b)Determine the safe tensile, shear and bearing loads and the efficiency for a 300 mm

section of single-riveted lap joint made from 6mm plates using six 16-mm diameter

rivets. Assume that the drilled holes are 1.5 mm larger in diameter than the rivets. The

na

values for the design limits for tensile, shear and bearing stress can be taken as 75, 60

and 131MPa, respectively.

n

4. (a)What do you understand by the single start and double start threads? Explain with

.a

neat diagrams.

(b)A steam engine cylinder has an effective diameter of 350mm and the maximum

steam pressure acting on the cylinder cover is 1.25N/mm2. Calculate the number and

w

size of studs required to fix the cylinder cover, assuming the permissible stress in the

w

studs as 33MPa.

w

5. Design a socket and spigot type of cotter joint to sustain an axial load of 100kN. The

material selected for the joint has the following design stresses. t = 120 MPa, c =

160 MPa and pb = 60 MPa

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Code No: R31035

R10 Set No: 1

for the drive shaft illustrated in Figure:1 consisting of a midmounted spur gear and

overhung pulley wheel. The shaft is to be manufactured using 817M40 hot rolled

alloy steel with UTS 1000MPa, YS 770MPa and Brinell Hardness approximately 220

BHN. The radius of the fillets at the gear and pulley shoulders is 3mm.The power to

be transmitted is 8 kW at 900 rpm.The pitch circle diameter of the 20 pressure angle

spur gear is 192 mm and the pulley diameter is 250mm.The masses of the gear and

pulley are 8 and 10 kg, respectively. The ratio of belt tensions should be taken as 2.5.

om

Profiled keys are used to transmit torque through the gear and pulley. A shaft nominal

reliability of 90 per cent is desired. Assume the shaft is of constant diameter for the

calculation.

.c

us

pl

ty

si

er

iv

un

Fig:1

7. Design a bush type flexible coupling to connect motor and centrifugal pump shafts.

Motor transmits 10 KW at 1440 RPM. Allowable stress in shear for shaft, key and

na

bolts are 40 MPa. Allowable bearing pressure for rubber bush is 0.3 MPa. Check for

stresses.

n

.a

installed in a hole with a diameter of 24mm.The application involves slow cycling and

w

a total life of 250 000 cycles is required. The maximum temperature of operation is

80C.

w

*****

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Code No: R31035

R10 Set No: 2

III B.Tech. I Semester Supplementary Examinations, June/July - 2014

Design of Machine Members-I

(Mechanical Engineering)

Time: 3 Hours Max Marks: 75

Answer any FIVE Questions

All Questions carry equal marks

*****

1. (a) A stepped shaft has maximum diameter 45 mm and minimum diameter 30 mm.

om

The fillet radius is 6 mm. If the shaft is subjected to an axial load of 10 kN, find the

maximum stress induced, taking stress concentration into account

(b)Explain in detail about the six theories of failure

.c

2. (a)Explain the influence of stress concentration in the design of machine elements

us

(b)Explain the significance of Goodmans line and Soderberg line in design of

members subjected to reversal of stresses.

pl

3. Design the longitudinal joint for a boiler for a steam pressure of 2 MPa. Diameter of

the boiler is 1 m. Select a double riveted butt joint with a required efficiency of 75%.

ty

Take the following allowable stresses. t = 80 MPa, = 60MPa, c = 120 MPa

si

4. (a)Explain the method of determining the size of bolt when the bracket carries an

eccentric load perpendicular to the axis of the bolt

er

(b)An eye bolt is to be used for lifting a load of 60 kN. Find the nominal diameter of

the bolt , if the tensile stress is not to exceed 100MPa. Assume coarse threads.

iv

un

5. Design a sleeve type of cotter joint to connect two tie rods subjected to an axial pull

of 60 kN. The allowable stress of C 30 material used for rods and cotters are t = 65

N/mm2, c = 75 N/mm2and = 35 N/mm2. Cast steel material used for the sleeve has

na

6. Determine the deflection of the stepped shaft illustrated in Figure 1 under a single

n

concentrated load.

.a

w

w

w

Figure 1

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Code No: R31035

R10 Set No: 2

7. Design a cast Iron flange coupling (protected type) to connect two shafts and

transmits a torque a 5000 Nm. The following permissible stresses may be used.

Permissible shear stress for shaft, bolt and key material = 50 MPa. Permissible shear

stress for CI = 16MPa

to a length of140mm.At a length of 170 mm the force must be 160N. A nominal

spring mean diameter of 35 mm has been proposed. The application involves slow

cycling and a total life of 150 000 cycles is required. The maximum temperature of

om

operation is 60C. Determine a suitable wire diameter for this application if ASTM

A232 is to be used.

.c

*****

us

pl

ty

si

er

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n na

.a

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Code No: R31035

R10 Set No: 3

III B.Tech. I Semester Supplementary Examinations, June/July - 2014

Design of Machine Members-I

(Mechanical Engineering)

Time: 3 Hours Max Marks: 75

Answer any FIVE Questions

All Questions carry equal marks

*****

om

1. (a) Discuss the factors influencing selection of an appropriate material for a machine

Element

(b)A weight of 1 kN is dropped from a height of 50 mm at the free end of a cantilever

.c

beam of effective length 300 mm. Determine the cross section of the cantilever beam

of square cross section if the allowable stress in the material of the beam is limited

us

to 80MPa.

2. shaft can transmit power of 20 KW at 1000 RPM. The actual torque transmitted by

pl

shaft is 60% of the mean torque calculated. Shaft is also subjected to a variable

bending moment of 500 N-m to 1000 N-m. The maximum bending moment occurs at

ty

the same instant as that of maximum torque. Determine the diameter of the shaft

required selecting suitable material. Take factor of safety 2, size factor = 0.85, and

si

surface factor = 0.8.

er

3. (a)What are the various permanent and detachable fastenings? Give a complete list

with the different types of each category.

iv

(b)Determine the maximum safe tensile load that can be supported by a 1 m section of

un

double riveted butt joint with 15 mm thick main plates and two 8 mm thick cover

plates. There are six rivets in each of the outer rows and seven rivets in each of the

inner rows. The rivets are all 20 mm in diameter. Assume that the drilled holes are 1.5

na

mm larger in diameter than the rivets. The values for the design limits for tensile,

shear and bearing stress can be taken as 75, 60 and 131MPa, respectively.

n

.a

(b)A bolt in a steel structure is subjected to a tensile load of 9 KN. The initial

tightening load on the bolt is 5 KN. Determine the size of the bolt taking allowable

w

w

of 500 RPM to mount a hub of length 60mm on a solid circular shaft of diameter 50

w

mm.

(b) Sketch and explain the types of riveted joint failure.

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Code No: R31035

R10 Set No: 3

6. A shaft is required to transmit 1 MW power at 240RPM. The shaft must not twist

more that 10 on a length of 15 diameters. If the modulus of rigidity for the material of

the shaft is 80 kN/mm2, find the diameter of the shaft and the shear stress induced.

A line shaft is to transmit 600 KW at 500RPM. The allowable shear stress for the

material of the shaft is 42 N/mm2 (42MPa). If the shaft carries a central load of 900N

and is simply supported between bearing 3 meter apart, determine the diameter of the

shaft. The maximum tensile or compressive stress in not exceed 50 MPa

om

7. Design a bushed pin type flexible coupling to transmit 90 KW at 1440 RPM for

connecting two shafts of diameter 60 mm. Assume bearing pressure on the bushes as

0.35N/mm2, allowable shear stress in the material of the pins as 45 N/mm2 and

.c

allowable bending stress in the material of the pin is 80 N/mm2

us

8. A helical extension spring is required to exert a force of 30 N when the length

between attachment locations is 70 mm and a force of 20 N at a length of 60mm.The

spring will be cycled through its load 100 times a day. ASTM A228 music wire steel

pl

has been proposed for the spring. The diameter of the spring should not exceed

20mm.Determine suitable dimensions for the spring wire diameter, number of coils

and mean diameter.

ty

*****

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er

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n na

.a

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Code No: R31035

R10 Set No: 4

III B.Tech. I Semester Supplementary Examinations, June/July - 2014

Design of Machine Members-I

(Mechanical Engineering)

Time: 3 Hours Max Marks: 75

Answer any FIVE Questions

All Questions carry equal marks

om

*****

1. (a).Discuss the factors influencing selection of appropriate value for the factor of

safety and List the factors which govern the selection of a material for a machine

.c

component

(b)A round steel bar having y = 800 MPa is subjected to the loads producing the

us

calculated stresses of P/A = 70MPa, TR/Jp = 200 MPa, My/J = 300 MPa and 4V/3A =

170MPa.

(i) Determine the safety factor with respect to initial yielding according to maximum

pl

shear stress theory and maximum distortion energy theory

(ii) Draw the sketch showing the location of maximum normal stress and maximum

ty

shear stress planes si

2. A shaft of circular cross section is subjected to a turning moment that fluctuates

between 800 kNm and 600 kNm and also a bending moment that fluctuates between +

er

500 kNm and 300 kNm. The material selected for the shaft has a shear stress value

of 100 MPa at endurance limit and a shear stress value of 120 MPa of the yield limit.

iv

Determine the diameter of the solid circular shaft taking a value of 2.50 for the factor

un

of safety. Surface factor, size factor and load factor can be taken as 0.90, 0.85 and 1.0

respectively. Shear stress concentration factor is 1.80 and the notch sensitivity is 0.95.

na

(b )A plate 100mm wide and 10mm thick is to be welded to another plate by means

of double parallel fillets. The plates are subjected to a static load of 80 kN. Find the

n

length of weld if the permissible shear stress in the weld does not exceed 55MPa.

.a

w

such bolts?

(b)Two machined parts are fastened together tightly by means of a 24mm tap bolt. If

w

the load tending to separate these parts is neglected, find the stress that is set up in the

bolt by the initial tightening?

w

5. (a)A 100mm shaft rotating at 100 RPM transmit 300 hp power is taken off through a

gear whose hub is 200 mm long. The key is made of steel having an ultimate shearing

stress of 350N/ mm2. Using a factor of safety of 5, determine the width of key

required.

(b)How are keys classified Draw neat sketches of different types of keys and state

their applications

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Code No: R31035

R10 Set No: 4

6. Determine the diameter of the drive shaft for a chain conveyor, which has the loading

parameters illustrated in Figure 1. A roller chain sprocket of 500 mm pitch diameter,

weighing 90 kg will be mid-mounted between two bearings. A 400mm, 125 kg roller

chain sprocket will be mounted overhung. The drive shaft is to be manufactured using

cold drawn 070M20 steel with UTS 1000MPa, YS 770MPa and Brinell Hardness

approximately 220 BHN..The shaft will carry a steady driving torque of 1600 N m

and rotate at 36 rpm. A sled runner keyway will be used for the overhung pulley and a

profile keyway for the mid-mounted pulley

om

.c

us

pl

ty

si

er

iv

Figure 1

un

7. Design a cast iron protective flange coupling to connect two shafts in order to transmit

7.5 KW at 720 RPM. the following permissible stresses may be used permissible

na

shear stress for shaft, bolt and key material = 33MPa. Crushing stress for bolt and key

material = 60 MPa. Shear stress for cast iron = 15MPa.

n

.a

(b) Classify springs according to their shape. Draw neat sketches indicating in each

case whether stresses are induced by bending or by torsion

w

*****

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2 of 2

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