Test/Date and Time Semester/year Course/Course Code Max Marks

III TEST/ 9-10 AM V SEM Year: 2020-2021 MACHINE DESIGN

20
17-03-2021 15ME53T
Name of Course coordinator : Jayadevappa E Units: 04,06 CO’s: CO4,CO6
Questi Questions MA C
CO PO
on no NOTE: USE OF DESIGN DATA HAND BOOK IS ALLOWED RKS L
Answer all questions
1 1. Design a protective type of cast iron flange coupling for a steel shaft
transmitting 15 kW at 200 r.p.m. and having an allowable shear stress of 40
MPa. The working stress in the bolts should not exceed 30 MPa. Assume
that the same material is used for shaft and key and that the crushing stress
is twice the value of its shear stress. The maximum torque is 25% greater
than the full load torque. The shear stress for cast iron is 14 MPa.
Or
Design a cotter joint to support a load varying from 30 kN in compression 10 A 04 1,2
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.
Or
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.
2 Explain with a neat sketch with examples five basic forms for the shape of
Product.
Or 05 U 06 2

Explain the meaning of different colours as per Morgan’s code.

3 Discuss the scope of ergonomics in product design.
Or 05 U 06 2
Explain man – machine joint system with a neat sketch.
2. There are five basic forms of the products, namely, step, taper, shear, streamline and sculpture, as shown in
Fig. 1.4. The external shape of any product is based on one or combination of these basic forms.

Fig. 1.4: Basic Types of Product Forms

(i) Step form:

The step form is a stepped structure having vertical accent. It is similar to the shape of a multistory
building.
(ii) Taper form: The taper form consists of tapered blocks or tapered cylinders.
(iii) Shear form: The shear form has a square outlook.
(iv) Streamline form:
The streamline form has a streamlined shape having a smooth flow as seen in automobile and airplane
structures.
(v) Sculpture form:
The sculpture form consists of ellipsoids, paraboloids and hyperboloids.

Colour is one of the major contributors to the aesthetic appeal of the product. Many colours are linked
with different moods and conditions.
The selection of the colour should be compatible with the conventions. Morgan has suggested the colour
code given in Table 1.1.
Table 1.1: Morgan Colour Code

Colour Meaning
 Red Danger, Hot
 Orange Possible’ Danger
 Yellow Caution
 Green Safe
 Blue Cold
 Grey Dull

3. The aim of ergonomics is to develop a comfortable, safe and thus a productive work system, by
incorporating human factors thinking and data into the plan.
This means designing the product or process to use the capabilities of the person,but at the same time to
respect their limitations.
For example, an automobile manufacturer will consider the range of physical size and strength of the
population of drivers who are expected to use a particular model to ensure that the seats are comfortable,
that the controls are readily identifiable and within reach, that there is clear visibility to the front and the
rear, and that the internal instruments are easy to read. Ease of entry and egress will also be taken into
account.

Fig. 1.10 shows the man-machine closed loop system. The machine has a display unit and a control unit.
 A man (user) receives the information from the machine display through the
sense organs.
 He (or she) then takes the corrective action on the machine controls using the
hands or feet.
 This man-machine closed loop system in influenced by the working
environmental factors such as: lighting, noise, temperature, humidity, air
circulation, etc.

Fig. 1.10: Man-Machine Closed Loop System

 The communication system between the man (user) and the machine consists of
the displays and the controls.