UNIT I

SATRESSES IN MACHINE MEMBERS: Simple- bending and torsional stress equations – Impact and
shock loading – criteria for design - strength and rigidity- calculation of principle stresses for various load
combinations-eccentric loading - theories of failure.

1. Classify the various types Machine Design.

2. What is the procedure adopted in the design of Machine elements.
3. Explain the factors influencing design and manufacturing considerations of design.

4. Enumerate the most commonly used engineering materials and state some important
properties and their engineering applications.
5. Write short notes on free cutting steel and stainless steel.
6. State the alloying elements added to steel and the effects they produce in steel
7. (a) Explain preferred numbers and their significance.
(b) BIS codes of steels
8. An unknown weight falls through 10 mm on a collar rigidly attached to the lower end of a
vertical bar 3 m long and 600 mm2 in section. If the maximum instantaneous extension is
known to be 2 mm, what is the corresponding stress and the value of unknown weight? Take
E = 200 kN/mm2.
9. State and explain various theories of failure under static loading.
10. A wall bracket, as shown in figure, is subjected to a pull of P = 5 kN, at 60° to the vertical.
The cross-section of bracket is rectangular having b = 3t . Determine the dimensions b and t
if the stress in the material of the bracket is limited to 28 MPa.

11. A bolt is subjected to a direct tensile load of 20 kN and a shear load of 15 kN. Suggest the
suitable size of bolt according i) maximum normal stress theory, ii) maximum shear stress
theory and iii) maximum distortion energy theory iv) Maximum principal strain theory v)
Maximum strain energy theory of elastic failures, if the yield stress in simple tension is 360
MPa. A factor of safety of 3.5 should be used. Take Poisson’s ratio as 0.25.
12. A hollow shaft is required to transmit 600 kW at 110 r.p.m., the maximum torque being 20%
greater than the mean. The shear stress is not to exceed 63 MPa and twist in a length of 3
metres not to exceed 1.4 degrees. Find the external diameter of the shaft, if the internal
diameter to the external diameter is 3/8. Take modulus of rigidity as 84 GPa.

UNIT II

DESIGN FOR FATIGUE STRENGTH:

Stress concentration- theoretical stress concentration factor - methods of reducing stress concentration.
Introduction- S-N Diagram-Low cycle fatigue-High cycle fatigue- Endurance limit-factors effecting
endurance limit- fluctuating stresses-Goodman-modified goodman and soderberg criteria-stresses due to
combined loading.

1. Explain the following terms in connection with design of machine members subjected to
variable load.
i. Endurance limit
ii. Size factor
iii. Surface finish factor
iv. Notch sensitivity.
2
(a) Describe the causes of stress concentration.
(b) Explain the endurance limit modifying factors.
(c) Describe fatigue stress concentration factor.

3 . (a) Explain endurance strength and fatigue strength.

(b) Describe the stress concentration factor and its significance.
(c) Explain the methods of reducing stress concentration.

4. (a) High cycle Fatigue and low cycle fatigue.

(b) Explain the significance of Goodman’s line and Soderberg line in design of members
subjected to reversal of stresses.
(c) Draw S-N curve for mild steel and explain its significance.

5. A machine member is made of plain carbon steel of ultimate strength 650 N/mm 2 and
endurance limit of 300 N/mm2. If the member is subjected to a fluctuating torsional moment
which varies from -200 N-m to 400 N-m. Design the member using (i) modified Goodman’s
equation and (ii) Soderberg equation.
6. A simply supported beam has a concentrated load at the centre which fluctuates from a value
of P to 4 P. The span of the beam is 500 mm and its cross-section is circular with a diameter of
60 mm. Taking for the beam material an ultimate stress of 700 MPa, a yield stress of 500 MPa,
endurance limit of 330 MPa for reversed bending, and a factor of safety of 1.3, calculate the
maximum value of P. Take a size factor of 0.85 and a surface finish factor of 0.9.
7. shaft can transmit power of 20 KW at 1000 RPM. The actual torque transmitted by 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 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 surface factor = 0.8.

8. A circular cross section cantilever beam having length 130 mm. subjected to a cyclic
transverse load of varying form -150 N to 350 N, FOS is 2, theoretical stress concentration factor
is 1.4, notch sensitivity factor is 0.9, ultimate strength is 540 MPa, yield strength is 320 MPa.
Size correction factor is 0.85. Endurance limit is 275 MPa, surface correction factor is 0.9 and
notch sensitivity factor is 0.9. Determine the diameter of the beam by (i) Goodman method and
(ii) Soderberg method.

9. A hot rolled steel shaft is subjected to a torsional moment that varies from +350 Nm to -115
Nm and an applied bending moment at a critical section varies from 445 Nm to 225 Nm. The
shaft is of uniform cross section. Determine the required shaft diameter. The material has an
ultimate strength of 550 MPa and yield strength of 410 MPa. Take the endurance limit as half the
ultimate strength, factor of safety of 2, size factor of 0.85 and a surface finish factor of 0.62.
(Using Goodman’s Line).

10. 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 + 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. Determine the diameter of the solid
circular shaft taking a value of 2.50 for the factor 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. (Using modified Goodman’s Line)

11. A steam engine of effective diameter 300 mm is subjected to a steam pressure of 1.5 N/mm2.
The cylinder head is connected by 8 bolts having yield point 330 MPa and endurance limit at 240
MPa. The bolts are tightened with an initial preload of 1.5 times the steam load. A soft copper
gasket is used to make the joint leak-proof. Assuming a factor of safety 2, find the size of bolt
required. The stiffness factor for copper gasket may be taken as 0.5.

UNIT III

BOLTED JOINTS: Design of bolts with pre-stresses–Design of joints under eccentric loading-bolt of
uniform strength.
COTTER AND KNUCKLE JOINTS: Design of sleeve and cotter & socket and spigot cotter joint-
knuckle joint

1. Design a cotter joint to connect two mild steel rods for a pull of 30 kN. The maximum
permissible stresses are 55 N/mm2 in tension, 40 N/mm2 in shear and 70 N/mm2 in crushing.
Draw a neat sketch of the joint.
2. Design a cotter joint of socket and spigot type which is subjected to a pull and push of 50 kN.
All the parts of the joint are made of the same material with the permissible stress as 70 MPa
in tension, 100 MPa in compression and 40 MPa in shear.

3. Two tie rods are to be connected by means of a sleeve and two steel cotters. The rods are
subjected to a tensile load of 40kN. Design the joint using the permissible stress in tension as
60MPa, in shear as 50MPa and in crushing as 120MPa. Draw a neat sketch and show all the
dimensions.

4. Design a knuckle joint to transmit 150 kN. The design stresses may be taken as 75 MPa in
tension, 60 MPa in shear and 150 MPa in compression.

5. Design a knuckle joint for a tie rod of a circular section to sustain a maximum pull of 70 kN.
The ultimate strength of the material of the rod against tearing is 420 MPa. The ultimate
tensile and shearing strength of the pin material are 510 MPa and 396 MPa respectively.
Determine the tie rod section and pin section. Take factor of safety = 6.
6. A steam engine of effective diameter 300 mm is subjected to a steam pressure of 1.5 N/mm2.
The cylinder head is connected by 8 bolts having yield point 330 N/mm 2 and endurance limit
at 240 N/mm2. The bolts are tightened with an initial preload of 1.5 times the steam load.
Assume a factor of safety 2. Find the size of bolt required the stiffness factor for copper
gasket may be taken as 0.5.
7. Determine the size of the bolts and the thickness of the arm for the bracket as shown in figure
if it carries a load of 40 kN at an angle of 60° to the vertical. The material of the bracket and
the bolts is same for which the safe stresses can be assumed as 70, 50 and 105 MPa in tension,
shear and compression respectively
8. A bracket is bolted to a column by 6 bolts of equal size as shown in figure. It carries a load of
50 kN at a distance of 150 mm from the centre of column. If the maximum stress in the bolts
is to be limited to 150 MPa, determine the diameter of bolt.

9. Discuss on bolts of uniform strength giving examples of practical applications of such bolts.
10. Derive an expression for the maximum load in a bolt when a bracket with circular base is
bolted to a wall by means of four bolts.

11. The base of a pillar crane is fastened to the foundation (a level plane) by eight bolts spaced
equally on a bolt circle of diameter 1.6 m. The diameter of the pillar base is 2 m. Determine the
size of bolts when the crane carries a load of 100 kN at a distance of 5 m from the centre of the
base. The allowable stress for the bolt material is 100 MPa. The table for metric coarse threads is
given below :

UNIT IV
DESIGN OF SHAFTS: Torsion of shafts-design for strength and rigidity with steady loading-ASME
codes for power transmission shafting-shafts under fluctuating loads and combined loads.
KEYS AND COUPLINGS: Types of keys-design of sunk key.
Couplings: Rigid and flexible couplings-Flange coupling-Bushed pin type flexible coupling.

1. Under what circumstances the hollow shaft preferred over solid shafts? Explain
 2. A line shaft transmits 25 KW power at 200 rpm by means of a vertical belt drive. The
diameter of the belt pulley is 1 m and the pulley over hangs 150 mm beyond the centre line of
the end bearing. The belt tensions act vertically downwards. The tension on the tight side of
the belt is 2.5 times on the slack side. The shaft is made of plain carbon steel 40C8 (Syt=380
N/mm2) and factor of safety is 2.5. The mass of the pulley is 25kgs. Determine the diameter of
the shaft.
3. Compare the weight, strength and stiffness of a hollow shaft of the same external diameter as
that of solid shaft. The inside diameter of the hollow shaft being 0.6 times the external
diameter. Both the shafts have same material and length.
4. In axial flow rotary compressor, the shaft is subjected to a maximum twisting moment of
1500N-m and a maximum bending moment of 3000N-m. Neglecting the axial load on the
shaft, determine the diameter of the shaft, if the allowable shear stress is 50N/mm 2. Assume
Kb = 1.5 and Kt = 1.2. If the shaft is to be a hollow one with di/do=4, what will be the
material saving in the hollow shaft. It is subjected to the same loading and of the same
material as the solid shaft. Compare the torsional stiffness of the two shafts.
5. A solid circular shaft of diameter d is subjected to a bending moment of Mb and torsional
moment of Mt. Prove that according to maximum shear stress theory

6. A propeller shaft is required to transmit 45kW power at 500 rpm. It is a hollow shaft, having
inside diameter 0.6 times of outside diameter. It is made of plain carbon steel and the
permissible shear stress is 84 N/mm2. Calculate the inside and outside diameters of the shaft.
7. A mild steel shaft transmits 20 kW at 200 r.p.m. It carries a central load of 900 N and is
simply supported between the bearings 2.5 metres apart. Determine the size of the shaft, if the
allowable shear stress is 42 MPa and the maximum tensile or compressive stress is not to
exceed 56 MPa. What size of the shaft will be required, if it is subjected to gradually applied
loads?
8. Design a rigid type of flange coupling to connect two shafts. The input shaft transmits 37.5kW
power at 180 rpm to the output shaft through the coupling. The service factor for the
application is 1.5. The design torque is 1.5 times of rated torque. Select suitable materials for
various parts of the coupling, design the coupling and specify the dimensions of the
components.
9. A horizontal shaft AD supported in bearings at A and B and carrying pulleys at C and D is to
transmit 75 kW at 500 r.p.m. from drive pulley D to off-take pulley C, as shown in figure.
Calculate the diameter of shaft. The data given is : P1 = 2 P2 (both horizontal), Q1 = 2 Q2
(both vertical), radius of pulley C = 220 mm, radius of pulley D = 160 mm, allowable shear
stress = 45 MPa.
10.

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

11. 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.

12. Design a Rigid flange coupling to transmit 20 KW at 900 RPM. The service factor is 1.35
for coupling motor. The shear stress for shaft, bolt and key = 40MPa; crushing stress for bolt
and key=80MPa; the shear stress for flange = 8MPa. Draw sketch of the coupling.

UNIT V
RIVETED AND WELDED JOINTS: Types of riveted joints-rivet materials-failures of riveted joints-
Joint Efficiency-Boiler Joints-Lozenge Joints-eccentrically loaded riveted joints.
Welded Joints – Types-Strength of butt and fillet welds-eccentrically loaded welded joints.

1. Classify the rivet heads according to Indian standard specifications.

2. Design the longitudinal joint for a 1.25 m diameter steam boiler to carry a steam pressure of
2.5 N/mm2. The ultimate strength of the boiler plate may be assumed as 420 MPa, crushing
strength as 650 MPa and shear strength as 300 MPa. Take the joint efficiency as 80%.Sketch
the joint with all the dimensions. Adopt the suitable factor of safety.
3. Sketch and discuss the various types of welded joints used in pressure vessels. What are the
considerations involved?
4. Design a double riveted butt joint with two cover plates for the longitudinal seam of a
boiler shell 1.5 m in diameter subjected to a steam pressure of 0.95 N/mm2. Assume joint
 efficiency as 75%, allowable tensile stress in the plate 90 MPa; compressive stress 140
MPa ; and shear stress in the rivet 56 MPa.
5. What is butt joint? Explain the advantages of butt joint over lap joint.
6. A plate 100 mm wide and 12.5 mm thick is to be welded to another plate by means of
parallel fillet welds. The plates are subjected to a load of 50 kN. Find the length of the
weld so that the maximum stress does not exceed 56 MPa. Consider the joint first under
static loading and then under fatigue loading.
7. What are the advantages of welded joints compared with riveted joints?
8. A triple riveted lap joint is to be made between 6mm plates. If the safe stresses are st =
84Mpa, ss = 60Mpa, and sc = 120Mpa, calculate the rivet diameter, rivet pitch, and
distance between rows of the rivet for the joint. Zig – Zag riveting is to be used. Sate
how the joint will fail.
9. What is the difference between Caulking and fullering? Explain with the help of neat
sketches.
10. A plate of 100mm wide and 10mm thick is to be welded with another plate by means of a
transverse welds at the ends. If the plates are subjected to a load of 70kN, find the size of
the weld for static as well as fatigue load. The permissible tensile stress should not
exceed 70MPa.
11. An eccentrically loaded lap riveted joint is to be designed for a steel bracket as shown in
figure. The bracket plate is 25 mm thick. All rivets are to be of the same size. Load on the
bracket, P = 50 kN ; rivet spacing, C = 100 mm; load arm, e = 400 mm. Permissible shear
stress is 65 MPa and crushing stress is 120 MPa. Determine the size of the rivets to be
used for the joint.

12. A bracket is riveted to a columm by 6 rivets of equal size as shown in Fig. 9.38. It carries a
load of 100 kN at a distance of 250 mm from the column. If the maximum shear stress in
the rivet is limited to 63 MPa, find the diameter of the rivet.
13. A plate 75 mm wide and 12.5 mm thick is joined with another plate by a single transverse
weld and a double parallel fillet weld as shown in
figure.The maximum tensile and shear stresses are 70 MPa
and 56 MPa respectively. Find the length of each parallel
fillet weld, if the joint is subjected to both static and fatigue
loading.

14. A 50 mm diameter solid shaft is welded to a flat plate

as shown in figure. If the size of the weld is 15 mm,
find the maximum normal and shear stress in the
weld.

15. A rectangular steel plate is welded as a cantilever to a

vertical column and supports a single concentrated load
P, as shown in figure Determine the weld size if shear
stress in the same is not to exceed 140 MPa.

UNIT VI
MECHANICAL SPRINGS:
Stresses and deflections of helical springs – Extension- compression springs – springs for fatigue
loading– Energy storage capacity –helical torsion springs-Co-axial springs-leaf springs

1. A co-axial spring consists of two helical compression springs, one inside the other. The free
length of the outer spring is 25 mm greater than the inner spring. The wire diameter and
mean coil diameter of the inner spring are 8 mm and 64 mm respectively. Also the wire
diameter and mean coil diameter of the outer spring are 10 mm and 80 mm respectively.
The numbers of active coils in inner and outer springs are 10 and 15 respectively.
Assume the same material for two springs and the modulus of rigidity of spring material
is 81370 N/mm2. Calculate
(i) The stiffness of the spring the deflection is from 0 to 25 mm
(ii) The stiffness of the spring the deflection is more than 25 mm.

2. Discuss the stresses in Helical Springs of circular wire.

3. Explain the construction of leaf spring.
4. What is nipping in a leaf spring? Discuss its role.
5. A helical compression spring made of oil tempered carbon steel is subjected to a load
which varies from 400N to 1000N. The spring index is 6 and the design factor of safety is 1.25.
If the yield stress in shear is 770MPa and endurance stress in shear is 350MPa. Find i) Size of
spring wire, ii) Diameters of the spring, iii) Number of turns of the spring, iv) free length of
spring. The compression of the spring at the maximum load is 30mm. The modulus of rigidity
for the spring material may be taken as 80kN/mm2.
6. A mechanism used in printing machinery consists of a tension spring assembled with a
preload of 30N. The wire diameter of spring is 2mm with a spring index of 6. The spring has 18
active coils. The spring wire is hard drawn and oil tempered having the shear stress 680MPa and
modulus of rigidity 80kN/mm2. Determine the initial torsional shear stress in the wire, spring rate
and the force to cause the body of the spring to its yield strength.

7. A locomotive semi-elliptical laminated spring has an overall length 1m and sustains a

load of 70kN at its centre. The spring has 3 full length leaves and 15 graduated leaves with
central band of 100mm width. All the leaves are to be stressed to 400 MPa when fully loaded.
The ratio of the total spring depth to that of width is 2. E= 210kN/mm2. Determine i) the
thickness and width of the leaves, ii) The initial gap that should be provided between the full
length and graduated leaves before the band load is applied and iii) The load exerted on the band
after the spring is assembled.
8. Design a close coiled helical compression spring for a service load ranging from 2250N
to 2750N. 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 is 84kN/mm2.
Neglect the effect of stress concentration. Draw a fully dimensioned sketch of the spring showing
details of the finish of the end coils.
9. Briefly explain the design of helical spring for fatigue loading.
10.

11. Why the circular cross section is most commonly used for spring and not others? Under
what circumstances the non- circular section would be recommended.
12. A lift system is provided with cushion springs at the bottom of lift. The lift is free to fall.
Springs are set in parallel. Specify the required number of springs if the
lift has free fall of 1.5m from rest. Weight of lift = 30kN Allowable
deflection per spring = 370 mm Number of active turns =15 Spring mean
coil diameter =30 mm
13. A semi-elliptical laminated spring is made of no.10.B.W.G. steel 50mm wide. The length
between the supports is 66.25cm and the band is 63 mm wide. The spring has two
full length and five graduated leaves. A central load if 158 kg is carried.
(a) Determine the maximum stress in each set of leaves for an initial condition of no stress in the
leaves.
(b) Draw to half or quarter full size the elevation and plan of the spring
(c) Determine the maximum stress if the initial stress is provided to cause equal stresses when
loaded.
(d) Determine the deflection in parts (a)and (b) respectively.

14. 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
ratio1.8. 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
(c) Maximum coil diameter
(d) Shear stress induced if shorter side is parallel to the spring axis. Permissible shear stress in
spring wire material is 300N/mm2 and modulus of rigidity is 0.8×105N/mm2.