Part –A - Answer the following (10*2=20)

1. Write short notes on Elasticity and plasticity.

2. Define Fits & mention its types?
3. Difference between keys & Splines? & Types of keys
4. Under what circumstances flexible couplings are used?
5. How is bolt designated? Give examples.
6. What is the minimum size for fillet weld?
7. What is surging of springs?
8. How does flywheel differ from that of governor?
9. State any two points to be considered for selection of bearings?
10. How is Sommerfield number calculated?
11. What is adaptive design? Where it is used? Give example
12. What are the various theories of failures?
13. A shaft of 750 mm long is subjected to shear stress of 40 MPa and has an angle of twist equal to 0.017 radian.
Determine the diameter of the shaft. Take G=80 GPa.
14. Name any two of the rigid and flexible couplings
15. What are the different types of cotter joints
16. Write any two advantages and disadvantages of welded joints over riveted joints.
17. A helical spring of rate 12 N/mm is mounted on the top of another spring of rate 8 N/mm. Find the force required to
give a deflection of 50mm.
18. What is the main function of a flywheel in an engine?
19. For journal bearing the maximum operating temperature must be less than 80ᴼc. Why?
20. What are the modes of failure of rolling contact bearing?
Part –B - Answer the following 5*13=65 marks
11 a i) What are the factors influencing machine design? Explain it (10)
a ii) Write the short notes on Fits & explain its types. (3)
OR
11 b A circular bar of 500 mm 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 effect 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 (13)
11. (a) A ‘C’ clamp is subjected to a maximum load of W, as shown in fig. if the maximum tensile stress in the clamp is limited to
140 N/mm2, find the value of W. (13).

(OR)
(b) A steel cantilever is 200 mm long. It is subjected to an axial load which varies from 150 N
(compression) to 450 N (tension) and also a transverse load at its free end which varies from 80 N up to
120 N down. The cantilever is of circular cross-section. It is of diameter 2d for the first 50 mm and of
diameter d for the remaining length. Determine its diameter taking a factor of safety of 2.Assume the
following values: Yield stress = 330MPa; Endurance limit in reversed loading = 300MPa; Correction
factors = 0.7 in reversed axial loading = 1.0 in reversed bending; Stress concentration factor = 1.44 for
bending = 1.64 for axial loading; Size effect factor = 0.85; Surface effect factor = 0.90; Notch sensitivity
index = 0.90 (13)

12 a) A steel solid shaft transmitting 15 kW at 200 r.p.m. is supported on two bearings 750
mm apart and has two gears keyed to it. The pinion having 30 teeth of 5 mm module is located 100 mm to the left of the
right hand bearing and delivers power horizontally to the right. The gear having 100 teeth of 5 mm module is located 150 mm
to the right of the left hand bearing and receives power in a vertical direction from below. Using an allowable stress of 54 MPa
in shear, determine the diameter of the shaft.. (13)
OR
12 b Design a cast iron protective type flange coupling to transmit 15 kW at 900 r.p.m. from an electric motor to a compressor.
The service factor may be assumed as 1.35. The following permissible stresses may be used: Shear stress for shaft, bolt and key
material = 40 MPa Crushing stress for bolt and key = 80 MPa Shear stress for cast iron = 8 MPa Draw a neat
sketch of the coupling. (13)
12. (a) A transmission shaft is supported on two bearings which are 1m apart power is supplied to shaft by means of a flexible
coupling which is located to the left of left hand bearing. Power is transmitted from the shaft by means of a belt pulley, 250 mm
diameter. Which is located at a distance of 300 mm from the left hand bearing? The mass of the pulley is 20 kg and the ratio of
belt tension on tight and slack sides is2:1. The belt tension act vertically downward. The shaft is made of steel with yield stress
300 N/mm2 and the factor of safety is 3. Determine the shaft diameter, if it transmits 10kW power at 360 rpm from the
coupling to the pulley. (13)
(OR)
(b) Determine the dimensions of flange coupling that connects a motor and a pump shaft. The power to be transmitted a
2kW at a shaft speed of 960 rpm. Select suitable materials for the parts of the coupling and list the dimensions. (13)

13 a A bracket carrying a load of 15 kN is to be welded as shown in Fig. Find the size of weld
required if the allowable shear stress is not to exceed 80 MPa.

OR

13 b A knuckle joint is required to withstand a tensile load of 25 kN. Design the joint if the
permissible stresses are: σt = 56 MPa; τ = 40 MPa and σc = 70 MPa. (13)

13.(a) Design and draw a cotter joint to support a load varying from 30 kN in compression to 30 kN
in tension. The material used is carbon steel for which the following allowable stresses may
be used. The load is applied statically. Tensile stress = Compressive stress = 50 MPa, Shear
stress = 35 MPa and crushing stress = 90 MPa. (13)
(OR)
(b) Determine the length of the weld run for a plate of size 120 mm wide and 15 mm thick to be
welded to another plate by means of 1. A single transverse weld; and 2. Double parallel fillet welds
when the joint is subjected to variable loads. (13)

14 a Design a close coiled helical compression spring for a service load ranging from 2250 N to 2750 N. The axial deflection of
the spring for the load range is 6 mm. Assume a spring index of 5. The permissible shear stress intensity is 420 MPa and
modulus of rigidity, G = 84 kN/mm2. Neglect the effect of stress concentration. Draw a fully dimensioned sketch of the
spring, showing details of the finish of the end coils. (13)
OR
14 b A punching machine makes 25 working strokes per minute and is capable of punching 25 mm diameter holes in 18 mm
thick steel plates having an ultimate shear strength of 300 MPa. The punching operation takes place during 1/10 th of a
revolution of the crank shaft.Estimate the power needed for the driving motor, assuming a mechanical efficiency of 95 per cent.
Determine suitable dimensions for the rim cross-section of the flywheel, which is to revolve at 9 times the speed of the crank
shaft. The permissible coefficient of fluctuation of speed is 0.1. The flywheel is to be made of cast iron having a working stress
(tensile) of 6 MPa and density of 7250 kg / m3. The diameter of the flywheel must not exceed 1.4 m owingNto space
restrictions. The hub and the spokes may be assumed to provide 5% of the rotational inertia of the wheel. Check for the
centrifugal stress induced in the rim. (13)
14.(a) A punching press pierces 35 holes per minute in a plate using 10 kN-m of energy per hole during each revolution. Each
piercing takes 40 per cent of the time needed to make one revolution. The punch receives power through a gear
reduction unit which in turn is fed by a motor driven belt pulley 800 mm diameter and turning at 210 r.p.m. Find the
power of the electric motor if overall efficiency of the transmission unit is 80 per cent. Design a cast iron flywheel to
be used with the punching machine for a coefficient of steadiness of 5, if the space considerations limit the maximum
diameter to 1.3m.Allowable shear stress in the shaft material = 50 MPa,Allowable tensile stress for cast iron = 4
MPa,Density of cast iron = 7200 kg / m3(13)
(OR)
(b)Determine the dimensions of an I-section connecting rod for a petrol engine from the following
data : Diameter of the piston = 110 mm, Mass of the reciprocating parts = 2 kg
Length of the connecting rod from centre to centre = 325 mm, Stroke length = 150 mm
R.P.M. = 1500 with possible over speed of 2500, Compression ratio = 4 : 1
Maximum explosion pressure = 2.5 N/mm2 (13)

15 a. A full journal bearing of 50 mm diameter and 100 mm long has a bearing pressure of 1.4 N/mm2. The speed of the journal
is 900 r.p.m. and the ratio of journal diameter to the diametral clearance is 1000. The bearing is lubricated with oil whose
absolute viscosity at the operating temperature of 75°C may be taken as 0.011 kg/m-s. The room temperature is 35°C. Find: 1.
The amount of artificial cooling required, and 2. The mass of the lubricating oil required, if the difference between the outlet
and inlet temperature of the oil is 10°C. Take specific heat of the oil as 1850 J / kg / °C (13)
OR

15 b A single row angular contact ball bearing number 310 is used for an axial flow compressor. The bearing is to carry a radial
load of 2500 N and an axial or thrust load of 1500 N. Assuming light shock load, determine the rating life of the bearing. (13)
15(a) Design a journal bearing for a centrifugal pump from the following data: Load on the journal = 20 000 N; Speed of the
journal = 900 r.p.m.; Type of oil is SAE 10, for which the absolute viscosity at 55°C = 0.017 kg / m-s; Ambient temperature of oil
= 15.5°C ; Maximum bearing pressure for the pump = 1.5 N / mm2. Calculate also mass of the lubricating oil required for
artificial cooling, if rise of temperature of oil be limited to 10°C. Heat dissipation coefficient = 1232 W/m2/°C.(13)
(OR)
(b) Select a single row deep groove ball bearing for a radial load of 4000 N and an axial load of 5000 N, operating
at a speed of 1600 r.p.m. for an average life of 5 years at 10 hours per day. Assume uniform and steady load.(13)
16 a) Design a journal bearing for 12 MW ,1000 rpm of steam turbine which is supported by two bearings. Take the
atmospheric temperature as 160 C and operating temperature of oil as 600C. Assume the viscosity of oil as 23 centipoises. (15)
OR
16 b) Design a journal bearing for a centrifugal pump with the following data.
Diameter of the journal = 150mm
Load on bearing = 40kN
Speed of journal = 900 rpm. (15)

16(a)The intercepted areas between the output torque curve and the mean resistance line of a turning moment
diagram for a multi cylinder engine, taken in order from one end are as follows: – 35, + 410, – 285, + 325, – 335, + 260,
– 365, + 285, – 260 mm2.The diagram has been drawn to a scale of 1 mm = 70 N-m and 1 mm = 4.5°. The engine speed
is 900 r.p.m. and the fluctuation in speed is not to exceed 2% of the mean speed. Find the mass and cross-section of
the flywheel rim having 650 mm mean diameter. The density of the material of the flywheel may be taken as 7200
kg / m3. The rim is rectangular with the width 2 times the thickness. Neglect effect of arms, etc.
(15)
(OR)
(b)Design a leaf spring for the following specifications for truck. Assume FOS =2.
Maximum load on springs=100 kN, No. of springs = 4,
Material of springs = Cr Va steel (σu = 1380 MPa and E=206 x 103MPa),
Span of spring = 1000 mm, Width of central band = 150 mm,
Permissible deflection = 100mm, Assume 2 full length leaves and 6 graduated leaves. (15)