THE OPEN UNIVERSITY OF SRI LANKA

DEPARTMENT OF MECHANICAL ENGINEERING

BACHELOR OF TECHNOLOGY HONORS IN ENGINEERING - LEVEL 04

DMX4306 – Design of Machine Elements

ACADEMIC YEAR – 2020/2021
Assignment # 2

INSTRUCTIONS

1. Answer all questions.

2. Write your registration number clearly on your answer script.
3. Send your answer scripts under registered cover to the address given below or put it into the
assignment box available at the Mechanical Engineering Research Laboratory, new Science and
Technology (S & T) building.

THE COURSE COORDINATOR – DMX4306

DEPARTMENT OF MECHANICAL ENGINEERING

THE OPEN UNIVERSITY OF SRI LANKA.

P.O.BOX 21, NAWALA, NUGEGODA.

4. Last date of submission : Refer the Activity Diary for the Date of Submission
5. No late submission will be accepted.

Question 01.

What are the two main types of flanges available? Simply describe each type. Consider two shafts
transmitting power to a shaft of same diameter. Show that both diameter of a clamp coupling db is , db =
where T, are torque transmitted coefficient of friction between mutt and shaft, no
of bolts, permissible tensile stress for bolt and diameter of shaft.

Consider a shaft of mild steel, which is designed to transmit 15kW at 300 rpm. If the shaft is to be
coupled to another shaft with flange coupling, design and make a neat dimensioned sketch for flange
coupling.

Given that,

Shear stress for shaft = 150 MPa

Shear stress for keys = 120 MPa
Shear stress for flanges = 210 MPa
Shear stress for bolts = 90 MPa
Tensile stress for shaft = 250 MPa
Tensile stress for key = 270 MPa

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For calculations, refer table 13.1 and table 13.2 for standard key sizes and number of bolts.

Table 13.1

Shaft diameter (mm) Key width (mm) Key thickness (mm)

12 5 5
17 6 6
22 8 7
30 10 8
38 12 8
44 14 9
50 16 10

Table 13.2

Shaft diameter (mm) 35 to 55 56 to 150 151 to 230 231 to 390

No. of bolts 4 6 8 10

Question 02.

A) Consider a shaft subjected to combined twisting moment (T) and bending moment (M). If  and
b are the shear stress and bending stress respectively, show that

(Hint: , )

B) Consider a shaft supported by two bearing at D, E located 600mm apart. The shaft is driven by a
motor connected to the pulley at end of the shaft B. Motor is placed horizontally, and the pulley
is of diameter 600mm and is of weight 1000N. The motor supplies a power of 20kN at 200 rpm
to the shaft which is transmitted through two pulleys to another. Both pulleys are of diameter
400mm, and are located at one end and at the center (A,C). They are connected the other
pulleys vertically. Assume that the maximum tension in the pulley belts is twice the other, and
consider the shear stress and bending stress to be 42MPa and 56MPa respectively.
i. Draw Bending Moments Diagrams for both horizontal and vertical forces.
ii. Find the equivalent twisting and bending moments.
iii. Find the minimum required diameter of the shaft.
iv. If the load applied is a gradually applied load, what would be the minimum required
diameter? (Consider km = 1.5, kt = 1)
v. If the allowable angular deflection between A & C is 0.25. Find the required diameter of the
shaft.

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Question 03.
What are the self-locking & back driving power screws? Where are they used?
Show that required to lift and lower a load P can be denoted as follows.

Where, Tu - torque required to lift the load

Td - torque required to lower the load
dp - pitch diameter
 - coefficient of friction between screw & Nut
L - lead
c - coefficient of friction in thrust bearing
dc - mean diameter of thrust collar
If a power screw of pitch 1.5 mm was used, where pitch diameter is 8 mm and collar diameter is
60 mm with sliding friction 0.15 and rolling friction 0.12 torque is applied on the power screw at
30rpm and with a power 40w.
I. Find the maximum axial load that can be applied upon lifting, using acme thread
(consider the efficiency of acme thread as 25%, neglecting thrust collar friction)
II. Considering same variables, find the maximum force, if a square thread was used.
III. Find the overall efficiency for two cases.
IV. Select the most appropriate thread type and reason out.
V. Find whether it is self-locking or not.

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Question 04.
I. Write down the general procedure in solving a design problem?
II. What is the moment of inertia?
III. Consider a merry-go-round rotating around its centre, as in the figure below.
w

Neglecting the seats, find the moment of inertia of the system, considering the setup as a single
rod pivoted at the centre, if L=3m, m=40kg
IV. If the merry-go-round is to rotate with an angular acceleration of 1 rad.s-2, find the
torque requirement of the system.
V. When two children are seated on the either sides, torque requirement was four times
the initial, if the merry-go-round rotates at 30 rpm, what would be the power
requirement?
VI. If each child weighs 15kg, draw the bending moment diagram for the rod (Assume the
children are seated on the end of the rod.
VII. If the maximum pressure that a seat can withstand is 0.1 bar and area of the seat is
(30cm X 30cm), what would be the maximum weight, that the seat can withstand?
(consider as safety factor of 3)

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Question 05.
A.
I. Show that the diameter of bolts under eccentric parallel load, can be expressed as

L1 W
L2

II. Consider the bracket shown in figure. A load of 20kN is applied on the bracket. If
L=300mm, L1=50mm and L2=150mm, find the suitable bolt size. If four bolts are used,
consider the tensile stress as 70 MPa for bolts. Is it possible for bolts to bear the load, if
the bolt size is increased by 2mm and the distance at which the force is applied is
increased to be 550 mm. if the bolt size used was same as in the first case, what are the
other possible methods to resist the load applied at L=550mm. check whether the
problem is solved by increasing no of bolts. If so, how many bolts are to be used? (hint:
increasing no of rows must be done only in the direction of Z.
B.
I. Name 4 types of failures that could occur in a rivet joint.
II. A lap joint is to be made between 7mm thick plates with a pitch of 250mm. The rivet
diameter is 10mm and the force to be applied on the plates is 10000N. if the ultimate
stress in tension, shear and crushing is 400 Mpa, 300 Mpa, and 620 Mpa respectively,
find the no of rivets per pitch.(consider a safety factor of 2.5)

C.

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 I. Show that the strength of a joint with a single transverse and double parallel fillet welds
can be expressed as follows.

P=strength of the joint

S=leg or size of the weld
= length of the transverse weld
=length of the double fillet weld
=tensile strength
=allowable shear stress

II. A plate of 12.5mm thickness and 50mm width is to be weld to another plate by means
of parallel fillet weld. If the total length of the weld formed is 65mm, find the maximum
load that can be applied upon the plates. Permissible shear stress for the material is 50
MPa while the tensile stress is 70 MPa.

III. Find the total weld length, if the weld is of double transverse fillet weld where two
plates of same dimensions are weld to bear the same load. (Safety factor 4,
allow12.5mm for the starting and ending of each transverse and parallel fillet weld
lengths, assumes that the transverse weld is throughout the plate width).

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