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ME6503 DESIGN OF MACHINE ELEMENTS LTPC3003
OBJECTIVES:
• To familiarize the various steps involved in the Design Process

• To understand the principles involved in evaluating the shape and dimensions of a
component
to satisfy functional and strength requirements.
• To learn to use standard practices and standard data
• To learn to use catalogues and standard machine components
(Use of P S G Design Data Book is permitted)
UNIT I
STEADY STRESSES AND VARIABLE STRESSES IN MACHINE MEMBERS 10
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Introduction to the design process - factors influencing machine design, selection of
materials based on mechanical properties - Preferred numbers, fits and tolerances –
Direct, Bending and torsional stress equations – Impact and shock loading – calculation
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of principle stresses for various load combinations, eccentric loading – curved beams –
crane hook and ‘C’ frame- Factor of safety - theories of failure – Design based on
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strength and stiffness – stress concentration – Design for variable loading.
UNIT II
SHAFTS AND COUPLINGS En 8
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Design of solid and hollow shafts based on strength, rigidity and critical speed – Keys,
keyways and splines - Rigid and flexible couplings.
UNIT III eer

TEMPORARY AND PERMANENT JOINTS
ing 9
Threaded fasteners - Bolted joints including eccentric loading, Knuckle joints, Cotter
joints – Welded joints, riveted joints for structures - theory of bonded joints.
.ne
UNIT IV
ENERGY STORING ELEMENTS AND ENGINE COMPONENTS 9
Various types of springs, optimization of helical springs - rubber springs - Flywheels
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considering stresses in rims and arms for engines and punching machines- Connecting
Rods and crank shafts.
UNIT V BEARINGS 9
Sliding contact and rolling contact bearings - Hydrodynamic journal bearings,
Somerfield Number, Raimondi and Boyd graphs, -- Selection of Rolling Contact
bearings.
TOTAL: 45 PERIODS
OUTCOMES:

 Upon completion of this course, the students can able to successfully design
machine Components
TEXT BOOK:
1. Bhandari V, “Design of Machine Elements”, 3rd Edition, Tata McGraw-Hill Book Co,
2010.
2. Joseph Shigley, Charles Mischke, Richard Budynas and Keith Nisbett “Mechanical
Engineering Design”, 8th Edition, Tata McGraw-Hill, 2008.
REFERENCES:
1. Sundararajamoorthy T. V. Shanmugam .N, “Machine Design”, Anuradha Publications,
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Chennai, 2003.
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2. Robert C. Juvinall and Kurt M. Marshek, “Fundamentals of Machine Design”, 4th
Edition, Wiley, 2005
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3. Alfred Hall, Halowenko, A and Laughlin, H., “Machine Design”, Tata McGraw-Hill
BookCo.(Schaum’s Outline), 2010
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4. Bernard Hamrock, Steven Schmid,Bo Jacobson, “Fundamentals of Machine
gin
Elements”,2nd Edition, Tata McGraw-Hill Book Co., 2006.
eer
5. Orthwein W, “Machine Component Design”, Jaico Publishing Co, 2003.
ing
6. Ansel Ugural, “Mechanical Design – An Integral Approach", 1st Edition, Tata
McGraw-Hill Book Co, 2003.
7. Merhyle F. Spotts, Terry E. Shoup and Lee E. Hornberger, “Design of Machine .ne
Elements” 8th Edition, Printice Hall, 2003.
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TABLE OF CONTENTS
PAGE
S.NO TOPIC
NUMBER
1 Aim and Objective of the subject 5
2 Detailed Lesson Plan 6
UNIT-I-STEADY STRESSES AND VARIABLE STRESSES IN MACHINE

MEMBERS
3 Part - A (2Marks Qn. &Ans.) 8
4 Part - B (13Marks Qn. &Ans.) 12
UNIT-II-SHAFTS AND COUPLINGS

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5 Part - A (2Marks Qn. &Ans.) 35
6w.E Part - B (13Marks Qn. &Ans.) 39
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UNIT-III-TEMPORARY AND PERMANENT JOINTS
7 Part - A (2Marks Qn. &Ans.)

En 68
8 Part - B (13Marks Qn. &Ans.)

gin 72
UNIT-IV-ENERGY STORING ELEMENTS AND ENGINE COMPONENTS
9 Part - A (2Marks Qn. &Ans.) eer 90
10 Part - B (13Marks Qn. &Ans.) ing 93
UNIT-V-BEARINGS .ne
11
12
Part - A (2Marks Qn. &Ans.)
Part - B (13Marks Qn. &Ans.)

118
121
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PART – C
( UNIT I – UNIT V )
13 Part – C (15 Marks Qn. & Ans.) 137
14 Industrial / Practical Connectivity of the Subject 168
15 Anna University Previous Year Question Papers 170

ME 6503 DESIGN OF MACHINE ELEMENTS LTPC3003
Aim and objective of the subject
 To design is either to formulate a plan for the satisfaction of a specified need or to

solve a problem.
 Attain knowledge on the principles and procedure for the design of mechanical
components.
 To develop an ability to identify, formulate, and solve engineering problems.
 To develop an ability to use the techniques, skills, and modern engineering tools
necessary for engineering practice.
 Develop an ability to apply knowledge of Mathematics, Science, and Engineering
ww  To analyze the stress on mechanical machine elements and understand, identify
w.E and quantify failure modes of machine elements

 To design machine elements to withstand load and deformations for a given
application. asy
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 To determine shape and dimensions of the component withstanding the load and
stresses in the working environment.
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 To develop an ability to design a system, component, or process to meet desired
needs within realistic constraints. eer
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 To understand the principles involved in evaluating the shape and dimensions of a

component to satisfy functional and strength requirements.
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To estimate life or performance under static, fatigue, impact and creep loading
conditions.
 To learn to use catalogues and standard machine components

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 To learn to use standard practices and standard data

DETAILED LESSON PLAN

Name of the Subject : ME 6503 DESIGN OF MACHINE ELEMENTS
TEXT BOOK:
1. Bhandari V, “Design of Machine Elements”, 3rd Edition, Tata McGraw-Hill Book Co, 2010.
2. Joseph Shigley, Charles Mischke, Richard Budynas and Keith Nisbett “Mechanical
Engineering Design”, 8th Edition, Tata McGraw-Hill, 2008.
REFERENCES:
1. Sundararajamoorthy T. V. Shanmugam .N, “Machine Design”, Anuradha Publications,
Chennai, 2003.
2. Robert C. Juvinall and Kurt M. Marshek, “Fundamentals of Machine Design”, 4th Edition,
Wiley, 2005
3. Alfred Hall, Halowenko, A and Laughlin, H., “Machine Design”, Tata McGraw-Hill
BookCo.(Schaum’s Outline), 2010
4. Bernard Hamrock, Steven Schmid,Bo Jacobson, “Fundamentals of Machine Elements”,2nd
Edition, Tata McGraw-Hill Book Co., 2006.
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5. Orthwein W, “Machine Component Design”, Jaico Publishing Co, 2003.
6. Ansel Ugural, “Mechanical Design – An Integral Approach", 1st Edition, Tata McGraw-Hill
Book Co, 2003.
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7. Merhyle F. Spotts, Terry E. Shoup and Lee E. Hornberger, “Design of Machine Elements”
8th Edition, Printice Hall, 2003.
Sl. No Unit asy

Topic / Portions to be Covered
Hours
Required
Cumulative Books
En / Planned
STEADY STRESSES AND VARIABLE STRESSES IN MACHINE MEMBERS
Hours Referred
1
Introduction to the design process -
factors influencing machine design
1 gin
1 T1,T2
2
Selection of materials based on
mechanical properties
1 2 eer
T1,T2
3 Preferred numbers, fits and tolerances 1

ing 3 T1,T2
4
Direct, Bending and torsional stress
equations
1 4
.ne T1,T2
6 1
Impact and shock loading
Calculation of principle stresses for
various load combinations–
1
1
5
6
T1,T2
T1,T2
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7 Eccentric loading 1 7 T1,T2
8 Curved beams 2 9 T1,T2
9 Crane hook and ‘C’ frame 1 10 T1,T2
10 Factor of safety – Theories of Failure 2 12 T1,T2

Design based on strength and stiffness
11 1 13 T1,T2
– stress concentration
12 Design for variable loading. 2 15 T1,T2

SHAFTS AND COUPLINGS

13 Design of solid based on strength 2 17 T1,T2
14 Design of solid shaft based on rigidity 2 19 T1,T2
Design of solid shaft based on critical
15 1 20 T1,T2
2 speed
Design of hollow shafts based on
16 2 22 T1,T2
strength
Design of hollow shaft based on
17 2 24 T1,T2
rigidity
Design of hollow shaft based on
18 1 25 T1,T2
critical speed
19 Keys, keyways and splines 1 26 T1,T2
20 Rigid couplings. 2 28 T1,T2
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21 Flexible couplings.
2 30 T1,T2
22w.E Threaded fasteners - Bolted joints

including eccentric loading
2 32 T1,T2
23
24 3
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Welded joints
Riveted joints for structures
4
2
36
38
T1,T2
T1,T2
25 Knuckle joints En 3 41 T1,T2
26 Cotter joints
gin 2 43 T1,T2
27 Theory of bonded joints.
ENERGY STORING ELEMENTS AND ENGINE COMPONENTS eer
2 45 T1,T2
28
Various types of springs, optimization
of helical springs
5 50 ing T1,T2
29
4
Rubber springs 1 51
.ne T1,T2
30
Flywheels considering stresses in rims
and arms for engines and punching
machines
5 56 T1,T2t
31 Connecting Rods 2 58 T1,T2
32 Crank shafts 2 60 T1,T2
BEARINGS
Sliding contact and rolling contact
33 4 64 T1,T2
bearings
34 5 Hydrodynamic journal bearings 2 66 T1,T2
Sommerfeld Number, Raimondi and
35 1 67 T1,T2
Boyd graphs
36 Selection of Rolling Contact bearings. 5 72 T1,T2

UNIT –I
STEADY STRESSES AND VARIABLE STRESSES IN MACHINE MEMBERS
PART –A
1. What is 'Adaptive design and Optimum design? (Dec 2007, 2011, 2012)
Adaptive design: It is a design process where a new product is developed just by

making small changes to the existing product.
Optimum design: Optimization is the process of maximizing a desired quantity or

minimizing an undesired one.
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2. List some factors that influence machine design. (Dec 2010)
Strength, stiffness, surface finish, tolerances, manufacturability,
w.E ergonomics and aesthetics, working atmosphere, cost, safety and reliability.
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3. Describe material properties hardness stiffness and resilience. (Apr 2009,
Nov 2009, Dec 2013)
En
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Hardness: It is the ability of the material to resist scratching and indentation
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Stiffness: It is the ability of the material to resist deformation under loading
Resilience: It is the ability of the material to resist absorb energy and to
resist shock and impact load.
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4. What is interchangeable manufacture?
Manufacturing process in which the produced parts that go in to assembly
may be Selected at random from a large number of plates.
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5. What are unilateral and bilateral tolerances?(May 2013)
A unilateral tolerance is tolerance in which variation is permitted only in
one direction from, the specified direction. Eg- 1800+0.060/-0.060
Bilateral tolerance is tolerance in which variartion is permitted in both
direction from the specified direction. eg- 1800 +0.060/-0.060

6. Differentiate between hardness and toughness of materials. (May 2014)

s.no Hardness Toughness
1. It refers yhe energy required to It refer the total energy which can be
deform a material used before the material breaks
2. Hardness is the characteristic of Toughness is the resistance to fracture
a solid material expressing its of a material when stressed
resistance to permanent
deformation
3. Hardness is the ability to Toughness is the measure of a
withstand localized deformation material ability to absorb energy
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7. List at least two methods to improve the fatigue strength. (Nov 2008)
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 Annealing
 Plastic coating
 Cold straining En
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8. Determine the force required to punch a hole of 20mm diameter in a 5mm
thick plate with ultimate shear strength of 250MPa. (Nov 2014)
ing
Given data:
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Diameter, d=20mm
Thickness, t= 5mm t
Shear strength, τ = 250MPa=250N/mm2
Solution: Force F= π d t τ = π.20.5.250 = 78.54KN

9. State the different between straight and curved beams. (Dec 2012)
Feature Straight beam Curved beam

Centroidal axis and Are coincident Are not coincident.
neutral axis Neutral axis is shifted
towards the centre of
curvature
Stress developed Same throughout the Different at inner and
section outer radii of the section
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10. Give some methods of reducing stress concentration.(Dec 2010)
i. Avoiding sharp corners.
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ii. Providing fillets.
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iii. Use of multiple holes instead of single hole
iv. Undercutting the shoulder parts.
En
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11. What are the factors that govern selection of materials while designing a
machine component? (Dec 2010)
 Required material properties eer
 Manufacturing easy ing
 Material availability
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 Cost
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12. Define stress concentration and stress concentration factor.(Apr 2009, May
2012, 2014)
Stress concentration is the increase in local stresses at points of rapid
change in cross section or discontinuities.
Stress concentration factor is the ratio of maximum stress at critical section
to the nominal stress. Kt=σmax/ σo
10

13. Explain notch sensitivity. State the relation between stress concentration
factor, fatigue stress concentration factor and notch sensitivity.
Notch sensitivity (q) is the degree to which the theoretical effect of stress
concentration is actually reached. The relation is, Kf = 1 + q (Kt-1)
14. What are the methods used to improve fatigue strength? (Dec 2013)
• Cold working like shot penning, burnishing.
• Heat treatment such as induction hardening, case hardening, nitrating
• Pre-stressing
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15.
w.E State Rankine theory of failure and its limitations.
asy
Rankine theory of failure: According to this theory, the failure or yielding occurs at a
point in a member when the maximum principal or normal stress in a bi-axial stress
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system reaches the limiting strength of the material in a simple tension test.
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Limitations: Since the maximum principal or normal stress theory is based on failure
in tension or compression and ignores the possibility of failure due to shearing stress,
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therefore it is not used for ductile materials. However, for brittle materials which are
relatively strong in shear but weak in tension or compression, this theory is generally
used.
ing
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16. Define modulus of resilience and proof resilience. (April 2017)
The total strain energy stored in a body is commonly known as resilience. Resilience
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is also defined as the capacity of a strained body for doing work on the removal of the
straining force.
Proof resilience is the maximum amount of strain energy stored in the body, when the
body is stressed upto elastic limit.
Modulus of resilience is is the maximum amount of strain energy stored in the body
per unit volume, when the body is stressed upto elastic limit.
11

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UNIT II
SHAFTS AND COUPLINGS
PART - A
1. Classify keys with its applications? (May 2012)
(a) Saddle key- It is applicable where light load is used.
(b) Sunk key – It is used to connect pulleys where is moderate load is applied.
(c) Woodruff key- Used to transmit small amount of torque in automotives.
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2. Discuss the forces on key? (Dec 2012, Dec 2014)
w.E (a) Shear force
(b) Bearing force asy

(c) Tensile force En
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3. What are the various stresses induced in shafts? (May 2014)
(a) Shear due to torsion eer

(b) Stress due to bending ing
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(c) Axial stress if an axial load acts.
4. Name any two of the rigid coupling? (May 2014)

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(a) Sleeve couplings
(b) Flange couplings
(c) Clamp couplings
35

5. What is the difference between rigid and flexible coupling? (May 2013, May
2016)
Rigid coupling: It is used in low speed applications where a good axial alignment
between connecting shafts can be achieved.
Flexible Coupling: The shafts having longitudinal, lateral and angular misalignment are
connected using flexible coupling.
6. How is the strength of a shaft affected by the keyway? (May2014)
The keyway cut into the shaft reduces the load carrying capacity of the shaft. This is due
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to the stress concentration near the corners of the keyway and reduction in the cross-
sectional area of the shaft. It other words, the torsional strength of the shaft is reduced.
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7. What is the main use of woodruff key? (Nov 2013)
asy
It is used to transmit less torque in automotive and machine tool industries. The keyway
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in the shaft is milled in a curved shape whereas the key way in the hub is usually straight.
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8. A shaft of 70 mm long is subjected to shear stress of 40 Mpa and has an angle of
eer
twist equal to 0.017 radian. Determine the diameter of the shaft. Take G= 80 Mpa?
(Nov 2013)
Given data: ing

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Length of the shaft, l= 750mm
Shear stress, τ= 40 N/mm2

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Angle of twist, ϴ=0.017 radian
Modulus of rigidity, G=0.8 ×105 N/mm2
To find:
Diameter of the shaft, d
36

Solutions:
Torsional moment of the shaft, Mt= (π/16) × τ × d3
Angle of twist, ϴ = (Mt×l)/(GJ)
Where J=(π/32) × d4
Angle of twist, 0.017=(2×40×750)/(0.8×105×d)
d=44.11 mm
Standard diameter, d=45 mm
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9. Why a hollow shaft has greater strength and stiffness than solid shaft of equal
weight? (Nov 2012)
w.E Stresses are maximum at the outer surface of a shaft. A hollow shaft has almost all
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the materials concentrated at the outer circumference. So, it has better strength and
stiffness for equal weight.
En
gin
10. Indicate the effects of providing key ways in the shaft? (Nov 2010)
eer
(a) It reduces strengths of the shaft because of material removal.
(b) It increases stress concentration.

ing
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11. What do you mean by stiffness and rigidity with reference to shafts? (Dec 2010)
Stiffness is the resistance offered by the shaft for twisting and rigidity is the resistance
offered by the shaft for lateral bending.
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12. Differentiate between keys and splines? (Nov 2011)
Key: A key is a piece of mild steel inserted between the shaft and hub or boss of the
pulley to connect these together in order to prevent relative motion between them. It is
always inserted parallel to the axis of the shaft. Keys are used as temporary fastenings
and are subjected to considerable crushing and shearing stresses.
37

Splines: Sometimes, keys are made integral with the shaft which fits in the keyways
broached in the hub. Such shafts are known as splined shafts or splines. These shafts
usually have four, six, ten or sixteen splines. The splined shafts are relatively stronger
than shafts having a single keyway. The splined shafts are used when the force to be
transmitted is large in proportion to the size of the shaft as in automobile transmission
and sliding gear transmissions. By using splined shafts, we obtain axial movement as
well as positive drive is obtained.
13. Under what circumstances flexible couplings are used? (Nov 2012)
(a) They are used to join the abutting ends of shafts when they are not in exact
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alignment.
w.E (b) They are used to permit an axial misalignment of the shafts without under
asy
absorption of the power, which the shafts are transmitting.
En
14. How is flexibility achieved in flexible coupling? (Nov 2010)
gin
(a) Kinematic arrangement such as loosely fit members
(b) Using rubber such as materials

eer
ing
15. Suggest suitable couplings for, shafts with parallel misalignment, shafts with
angular misalignment of 100, shafts in perfect alignment?
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Flexible coupling such as spring coupling can be used for shafts with parallel
misalignment. Universal coupling is suitable for shafts with angular misalignment of t
100 . Rigid coupling can be used for shafts in a perfect alignment.
16. Define equivalent torsional moment of a shaft. (April 2017)
The expression M2 + T 2
is known as equivalent twisting moment and is
denoted by Te. The equivalent twisting moment may be defined as that twisting
moment, which when acting alone, produces the same shear stress (τ) as the actual
twisting moment.
38

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UNIT- III
PART - A
1. How is a bolt designated? Give example. (Dec 2006,Apr 2009)

A thread is designated with Letter M followed by Nominal diameter in mm and
Pitch in mm [for fine pitches only].If coarse pitches are used then P value is
omitted.
Thus M20×2.5 means, Nominal diameter is 20mm, 2.5mm pitch, fine thread.
M20 means, 20mm nominal diameter with coarse threads
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2. Why are ACME threads preferred over square thread for power screw?(Nov
w.E
2014)
ACME threads is easier to machine and it is stronger than square
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threads. ACME threads are thicker and wider and operate better in environments with
dirt and debris.
En
3. What are the various initial stresses developed due to screwing up in bolted
joints? (Dec 2010)
gin
 Tensile stresses
 Torsional shear stress
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 Shear stress ing
 Compressive and bending stress .ne
4. Under what force, the big end bolts and caps are designed.(Dec 2011)
The big end bolts and caps are designed for inertia force due to
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reciprocating parts
5. What is gib? Why it is provided in a cotter joint?(Dec 2013)
Gib is an element made of mild steel with thickness equal to the cotter. A
gib is used in combination with the cotter to provide the following advantages
 Reduce bending of socket end
 Increase the bearing area of contact between the mating surfaces.
68

6. What are the different types of cotter joints? (May 2014)

 Socket and spigot cotter joint
 Sleeve and cotter joint
 Gip and cotter joint
7. Why are welded joints preferred over riveted joints? (Nov 2003, Apr2008,
Apr 2009)
Material is saved in welded joints and hence the machine element will be light if
welded joints are used instead of riveted joints. Leak proof joints can be easily
obtained by welded joints compared riveted joints.
8. Define the term self locking of power screws? (Apr 2004,Dec 2012, May
ww 2013)
If the friction angle is greater than helix angle of the power screw, the torque
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required to lower the load will be positive, indicating that an effort is applied to lower
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the load. This type is screw is known as self locking screw. The efficiency of the self
locking screw is less than 50%.
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9. What is the minimum size for fillet weld? If the required weld size from
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strength consideration is too small how will you fulfill the condition of
minimum weld size? (Nov 2008)
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It is the defined as the minimum size of the weld for a given thickness of the
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thinner part joined or plate to avoid cold cracking by escaping the rapid cooling
10. Name the possible modes of failure of riveting joint. (Nov 2008, Dec
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2012,May 2012)
1. Crushing of rivets
2. Shear of rivets
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3. Tearing of the plate at the edge
4. Tearing of the plate between rivets.
69

11. What is meant by the efficiency of the riveted joint? (Dec 2010)
The efficiency of a riveted joint is defined as the ratio of the strength of riveted
joint to the strength of the un-riveted or solid plate.
η = Least of Tearing Resistance, Shearing resistance and Crushing Resistanace
p x t x σt
Where, p = Pitch of rivets, t= thickness of plate and σt = Permissible Tensile stress
of the plate material.
12. What are the reason of replacing riveted joint by welded joint in modern
equipment.(Dec 2010)
ww Material is saved in welding joints and hence the machine element will be light if
welded joint are used instead of riveted joints. Leak proof joints can be easily
w.E
obtained by welded joints compared riveted joints.
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13. State the two types of eccentric welded connection (Dec 2013)
 Welded connections subjected to moment in a plane of the weld
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 Welded connections subjected to moment in a plane normal to the plane of
the weld.
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14. What is caulking and fullering?
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In order to make the joints leak proof or
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fluid tight in pressure vessels like steam
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boilers, air receivers and tanks etc. a process
known as caulking is employed. In this
process, a narrow blunt tool called caulking
tool, about 5 mm thick and 38 mm in breadth,
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is used. The edge of the tool is ground to an angle of 80°. The tool is moved after
each blow long the edge of the plate, which is planed to a bevel of 75° to 80° to
facilitate the forcing down of edge. It is seen that the tool burrs down the plate at A
in Fig. forming a metal to metal joint. In actual practice, both the edges at A and B
are caulked. The head of the rivets as shown at C are also turned down with a
caulking tool to make a joint steam tight. A great care is taken to prevent injury to
the plate below the tool.
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Fullering: A more satisfactory way of making the joints staunch is known as

fullering which has largely superseded caulking. In this
case, a fullering tool with a thickness at the end equal to
that of the plate is used in such a way that the greatest
pressure due to the blows occur near the joint, giving a
clean finish, with less risk of damaging the plate. A
fullering process is shown in Fig.
15. Differentiate with a neat sketch the fillet welds subjected to parallel loading
and transverse loading. (Apr-04, May-14)
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UNIT-IV
ENERGY STORING ELEMENTS AND ENGINE COMPONENTS
PART - A
1. Why springs are used in the machine? ( Dec 2010)

Springs are used in the machines to provide cushioning effect or reduce the effect of
shock or impact loading.
2. State any two functions of springs. (Dec 2006)
To measure forces in spring balance, meters and engine indicators.
To store energy.
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3. What is surge in springs? (May 2013)
w.EThe material is subjected to higher stresses which may cause early fatigue failure.
This effect is called as spring surge.
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4. What is meant by semi elliptical leaf spring? (May 2014)
The spring consists of number of leaves which are held together by U- clips. The
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long leaf fastened to the supported is called master leaf. Remaining leaves are called
graduated leaves.
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5. What is the purpose of flywheel that is used in an IC engine? (Dec 2013)
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A flywheel is a heavy rotating mass which is placed between the power source and
the driven member to act as a reservoir of energy. The primary function of flywheel
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is to act as an “energy accumulator”. It will absorb energy when demand is less than
the supply of energy and will release it when the demand is more than the energy
being supplied. t
6. How does the function of flywheel differ from that of governor? (Dec 2012)
Governor regulates the mean speed of an engine when there are variations in the
load, e.g. when the load on the engine increases, it becomes necessary to increase the
supply of working fluid. On the other hand, when the load decreases, less working
fluid is required. The governor automatically controls the supply of working fluid to
the engine with the varying load condition and keeps the mean speed within certain
limits.
90

Flywheel does not maintain a constant speed, it simply reduces the fluctuation of
speed. In other words, a flywheel controls the speed variations caused by the
fluctuation of the engine turning moment during each cycle of operation. It does not
control the speed variations caused by the varying load.
7. Define the co-efficient of fluctuation of speed in case of flywheel. (Nov 2014)
When the fly wheel absorbs energy, its speed increases and when it releases the
energy, its speed decreases. N1 and N2 be the maximum and minimum speeds and N
ww is the average speed.
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The difference between the maximum and minimum speeds during a cycle is called
the maximum fluctuation of speed. The ratio of the maximum fluctuation of speed to
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the mean speed is called coefficient of fluctuation of speed.
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Cs or Ks = ( N1 -N2 ) / N
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8. Under what circumstances Bellevellie springs used? (Dec 2010)
When large force is applied and deflection must be small. When space availability
is small.
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9. Distinguish between close coiled and open coiled springs. (Nov 2014)
Open coiled spring;
The wires are coiled such that there is a gap between the two consecutive.ne
turns. Helix angle is larger than 100.Both torsional and bending stresses are
significant.
t
Closed coiled spring:
The wires are coiled very closely, each turn is nearly at right angles to the
axis of helix. Helix angle is smaller than 100. Torsional Stresses are predominant.
10. Mention any four types of springs. (May 2012)
Helical Spring Conical Spring
Spiral Spring Disc or Bellville Spring
Leaf Spring.
91

11. Why leaf springs are made in layers instead of single plate? (Dec 2010)
Leaf springs are made in layers because,
1. To have equal stress
2. To achieve economical design
12. Define spring Index and stiffness. (DEC 2011)
The ratio of mean or pitch diameter to the diameter of wire for the spring is called
spring index. Stiffness is the ratio of load to the deflection.
13. What are different styles of end for helical compression spring? (Nov
2009)
ww Plain end
w.E Plain and ground
Squared
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Squared and ground
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14.
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Why piston end of a connecting rod kept smaller than the crank pin end?
(Dec 2010)
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The piston end of the connecting rod experiences less bending moment than crank
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end. Hence on the basis of beam of uniform strength the piston end of the connecting
rod is smaller.
15. At what angle of the crank the twisting moment is maximum in the
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crankshaft? ( Dec 2011)
The crank angle for maximum twisting moment lies between 250 and 350 from TDC
for petrol engines and between 300 and 400 for diesel engine.
t
16. What are the forces acting on connecting rod? ( April 2017)
The external forces acting on connecting rod are
1. Forces due to gas or steam pressure and inertia of reciprocating parts, 2. Inertia
forces.
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UNIT-V
BEARINGS
PART - A
1. How are bearings classified? (Dec 2010 & MAY 2014)

Depending upon the type of contact
a. Rolling element bearing
b. Sliding contact bearing
Depending upon the type of rolling element
ww a. Ball bearing
w.E b. Roller bearing

2. What is a journal bearing? List any two applications. (Nov 2006, May 2013 &
May 2014)
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the rotating shaft. En
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3. Classify the sliding contact bearings according to the thickness of layer of the
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lubricant between the bearing and the journal.( May 2012)
a. Thick film type
b. Thin film type ing
c. Hydrostatic bearings
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d. Hydrodynamic bearings
4. For a journal bearing, the maximum operating temperature must be less t
than 80oC. why?(Dec 2010)
Temperature rise will result in the reduction of the viscosity of the oil used
in the bearing. It would lead to metal to metal contact therby affecting the
bearing performance and life.
5. What is known as self acting bearing? (NOV 2007)
The pressure is created within the system due to rotation of the shaft known
as self acting bearing.In hydro dynamic bearing, what are factors which
influence the formation of wedge fluid film? (Nov 2014)
118

1. The contact surfaces must meet at a slight angle to allow the formation
of the lubricant wedge.
2. The fluid viscosity must be high to maintain an adequate film thickness
to separate the contacting surfaces at operating speeds.
6. Explain the term dynamic load carrying capacities of rolling contact bearing.
( Dec 2012)
The basic dynamic load rating is defined as the constant stationary radial load (in
case of radial ball or roller bearings) or constant axial load (in case of thrust ball
or roller bearings) which a group of apparently identical bearings with stationary
outer ring can endure for a rating life of one million revolutions (which is
ww equivalent to 500 hours of operation at 33.3 r.p.m.) with only 10 per cent failure.
7. What are the types of radial ball bearing? ( May 2012)
w.E 1. Deep groove ball bearing
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2. Self angular ball bearing
3. Angular contact ball bearing
4. Filing notch bearing.
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8. What is the application of thrust bearing? ( Dec 2010)
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Thrust bearings are used to support axial loads imposed on the rotaing
elements.
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9. What is meant by life of anti-friction bearing? ( Apr 2008 & May 2013)
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For an individual rolling bearing, the number of revolutions which one of
the bearing rings makes in relation to the other rings under the prevailing
working conditions before the first evidence of fatigue develops in the
material of one of the rings or rolling elements.
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10. List any four advantages to rolling contact bearings over sliding contact
bearings. (Apr 2009)
1. Starting friction is low
2. Lubrication is simple
3. It requires less axial space
11. State the disadvantages of thrust ball bearing. (Apr 2009)
1. High initial cost
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3. Noisy operation at very high speed.

w.E 4. Life is finite
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12. Define static capacity of bearing. (Nov 2014)
En
It is defined as load acting on a non rotating bearing under which permanent
deformation is 0.0001 times the ball or roller diameter.
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13. Explain the term dynamic load carrying capacities of rolling contact
bearing. (Nov 2004)
eer
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It is defined as the radial load in radial bearings that can be carried for a
minimum life of one million revolutions.
14. What are the modes of failure of rolling contact bearing? ( Dec 2010) .ne
1. Flaking or surface fatigue, 2. Peeling, 3. Scoring, 4. Fretting, 5.Creep t
15. What are anti friction bearings? (April 2017)
Advantage of a rolling contact bearing over a sliding bearing that it has a low
starting friction. Due to this low friction offered by rolling contact bearings,
these are called antifriction bearings.
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Industrial / Practical Connectivity of the Subject:
Mechanical engineering design involves all the disciplines of mechanical

engineering. Design results in the creation of something having a physical reality. The
product must be functional, safe, reliable, competitive, usable, manufacturable, and
marketable.
Machine Design is the application of subjects mathematics, kinematics, statics,

dynamics, mechanics of materials, engineering materials, material science, engineering
drawing, thermodynamics, electrical theory, hydraulics, engines, turbines, pumps etc.
ww Industries like Automotive, Industrial Machinery, power Generation, Production
w.E
and consumer appliance offers mechanical design services in product design, analysis,
Re-engineering, reverse engineering , prototyping, Part / Assembly Modelling, detailing
and drafting.
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The engineer has a great variety of tools and resources available to assist in the
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solution of design problems. Machine drawing is the integral part of the machine design,
since all the components or the machines that have been designed should be drawn to
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manufacture them as per the specifications.Computer-aided design (CAD) software
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allows the development of three-dimensional (3-D) designs from which conventional
two-dimensional orthographic views with automatic dimensioning can be produced.
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Manufacturing tool paths can be generated from the3-D models, and in some cases, parts
can be created directly from a 3-D database by using a rapid prototyping and
manufacturing method (stereolithography). Another advantage of a 3-D database is that it
t
allows rapid and accurate calculations of mass properties such as mass, location of the
center of gravity, and mass moments of inertia. Other geometric properties such as areas
and distances between points are likewise easily obtained. Software packages are
CATIA, UNIGRAPHICS, Solid Edge, Solid Works, Pro -E , AUTOCAD Inventor,
Mater Cam.
168

Engineering based software for mechanical engineering applications are finite-

element analysis (FEA) programs for analysis of stress and deflection , vibration, and
heat transfer (e.g., Algor, ANSYS, and MSC/NASTRAN), computational fluid dynamics
(CFD) programs for fluid-flow analysis and simulation (e.g., CFD++, FIDAP, and
Fluent); and programs for simulation of dynamic force and motion in mechanisms (e.g.,
ADAMS, DADS, and Working Model).
Non-engineering-specific computer-aided applications include software for word

processing, spreadsheet software (e.g., Excel, Lotus, and Quattro-Pro) and mathematical
solvers (e.g., Maple, MathCad, Matlab, Mathematica, and TKsolver).
ww
It is difficult, but extremely important, to keep of past and current developments in
engineering field. Some sources of information are:
w.E
• Libraries (community, university, and private). Engineering dictionaries and
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encyclopedias, textbooks, monographs, handbooks, indexing and abstract services,
journals, translations, technical reports, patents, and business sources / brochures /
catalogs. En
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• Government sources. Departments of Defense, Commerce, Energy, and Transportation;
ISRO, DRDO,CSIR, IGCAR, HAL, IIT's, NIT's eer
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• Professional societies. American Society of Mechanical Engineers, Society of
Manufacturing Engineers, Society of Automotive Engineers, American Society for .ne

Testing and Materials, and American Welding Society. t
• Commercial vendors. Catalogs, technical literature, test data, samples, and cost
information.
• Internet. The computer network gateway to websites associated with most of the
categories listed above.
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ME6503 DESIGN OF MACHINE ELEMENTS LTPC3003

• To familiarize the various steps involved in the Design Process

UNIT III eer

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1. Sundararajamoorthy T. V. Shanmugam .N, “Machine Design”, Anuradha Publications,

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1 Aim and Objective of the subject 5

2 Detailed Lesson Plan 6

UNIT-I-STEADY STRESSES AND VARIABLE STRESSES IN MACHINE

3 Part - A (2Marks Qn. &Ans.) 8

4 Part - B (13Marks Qn. &Ans.) 12

UNIT-II-SHAFTS AND COUPLINGS

6w.E Part - B (13Marks Qn. &Ans.) 39

7 Part - A (2Marks Qn. &Ans.)

8 Part - B (13Marks Qn. &Ans.)

UNIT-IV-ENERGY STORING ELEMENTS AND ENGINE COMPONENTS

9 Part - A (2Marks Qn. &Ans.) eer 90

10 Part - B (13Marks Qn. &Ans.) ing 93

Part - B (13Marks Qn. &Ans.)

14 Industrial / Practical Connectivity of the Subject 168

15 Anna University Previous Year Question Papers 170

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ME 6503 DESIGN OF MACHINE ELEMENTS LTPC3003

Aim and objective of the subject

 To design is either to formulate a plan for the satisfaction of a specified need or to

w.E and quantify failure modes of machine elements

 To learn to use catalogues and standard machine components

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DETAILED LESSON PLAN

Sl. No Unit asy

3 Preferred numbers, fits and tolerances 1

8 Curved beams 2 9 T1,T2

9 Crane hook and ‘C’ frame 1 10 T1,T2

10 Factor of safety – Theories of Failure 2 12 T1,T2

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SHAFTS AND COUPLINGS

22w.E Threaded fasteners - Bolted joints

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STEADY STRESSES AND VARIABLE STRESSES IN MACHINE MEMBERS

Adaptive design: It is a design process where a new product is developed just by

Optimum design: Optimization is the process of maximizing a desired quantity or

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6. Differentiate between hardness and toughness of materials. (May 2014)

ww at the surface. without breaking or fracture

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Feature Straight beam Curved beam

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• Cold working like shot penning, burnishing.

• Heat treatment such as induction hardening, case hardening, nitrating

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