MD - IES CONVENTIONAL 1995-2015

1995 PAPER-2
26. A motor drives a main shaft by means of
a flat belt. The diameters of the pulleys on
the motor shaft and the main shaft , are
450 mm and 750 mm respectively.
Another pulley of diameter 500 mm
drives a counter shaft having a pulley of
diameter 700mm. The pulley of diameter
500mm is mounted on the main shaft. If
the slip on each drive is 3 percent,
calculate the speed of counter shaft if
motor runs at 1400rpm. (20)
1996 – Paper - 2
27. An automotive single-plate clutch consists
of a pair of contacting surfaces. The inner
and outer diameters of friction plate are
120 mm and 250 mm respectively. The
coefficient of friction is 0.25 and the total
axial force is 15 kN. Calculate the power
transmitting capacity of the clutch plate of
500 rpm using (i) uniform wear theory
and (ii) uniform pressure theory. (24)
28. A transmission shaft supporting two
pulleys A and B are mounted between two
bearing and as shown in Figure.
Power is transmitted from pulley A to B.
The shaft is made of plain carbon steel
having ultimate tensile strength = 600
N/mm² and yield strength = 380 N/mm².
Determine the shaft diameter on the basis
of torsional rigidity, if the permissible
angel of twist between two pulleys is 0.5°
and the shear modulus of the material is
. The permissible shear stress
may be taken as 30% of the yield strength
of 18% of the ultimate tensile strength,
whichever is minimum, Check for its-
safety. (24)
1997 Paper -2
29. A square threaded bolt of mean diameter
24 mm and pitch 5 mm is tightened by
screwing a nut, whose mean diameter of
bearing surface is 50 mm. If the
coefficient of friction for nut and bolt is
0.1 and that for nut and bearing surface is
0.15, find the force required at the end of
a spanner 0.5 m long, when the load on
the bolt is 12 kN. (15)
30. A V-belt of 6.0 cm² cross-section has a
groove angle of 40° and an angle of lap of
150°  = 0.1. The mass of belt per meter
run is 1.2 kg. The maximum. allowable
stress in the belt is 850 N/cm2 Calculate
the horse power that can be transmitted at
a belt speed of 30 m/s. (20)
31. A mild steel shaft has to transmit 100 hp
at 200 rpm.
Design a cast iron flange coupling for the
shaft. The allowable stresses are as
follows :
Shear stress for shaft and key =40 N/mm²
Shear stress for bolts = 28 N/mm²
Shear stress for C.I. coupling = 20 N/mm²
Take bearing stress as twice the shear
stress value and number of bolts for the
coupling as 6.
Sketch the Coupling showing various
dimensions. (30)

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 MD - IES CONVENTIONAL 1995-2015
1998 Paper - 2
32. The semi-circle angle of a cone clutch is
12.5° and the contact surfaces have a
mean diameter of 80 mm. The coefficient
of friction is 0.32.
(i) What is the minimum torque
required to produce slipping of the
clutch for an axial force of 200 N?
If the clutch is used to connect an
electric motor with a stationary
flywheel,
(ii) what is the time needed to attain
the full speed and
(iii) the energy lost during slipping?
Motor speed is 900 rpm and the moment
of inertia of the flywheel is 0.4 kg m2.
(iv) What are the considerations in the
selection of plate clutches and cone
clutches? (20)
1999 PAPER - II
33. A 100 mm dia shaft operating at 2000
rev/min is supported by means of a 150
mm long full journal bearing which is
subjected to a radial load of 43 kN.
Assume (N /P) = 30 x 10-6. Determine
(i) the coefficient of friction using
McKee equation
which is given by
f = 0.326 (N/P)D/C + K
take D/C = 1000, K = 0.002.
(ii) bearing pressure in MN/m2.
(iii) heat generated. (10)
2000 Paper - 2
34. A rope pulley is designed to transmit 30
kW. Diameter of pulley = 360 mm. Speed
= 120 rpm. Angle of groove = 45°. Angle
of lap on smaller pulley = 170°.
Coefficient of friction = 0.27. Number of
2
ropes = 10. Mass of the rope = 55C2 kg/m.
Length and working tension of rope is
limited to 125 C2 kN, where C is the
circumference of rope in meter. Find
(i) the initial tension and
(ii) diameter of each rope. (20)
2001 Paper-2
35. Design a set of stepped pulleys to drive a
machine from a counter-shaft that runs at
220 rpm. The centre distance between the
twos sets of pulleys is 2 m. The diameter
of the smallest step on the countershaft is
160 mm. The machine is to run at 80, 100
and 130 rpm and should be able to rotate
in either directions. Find the length of the
belt required for both cases. (15)
2002 PAPER - II
36. A transmission shaft, rotating at 500
r.p.m., drives a milling machine which
requires 3.75 kW at 750 r.p.m. A 300 mm
diameter cast iron pulley is mounted on
the transmission shaft. A preliminary
design proposes using a belt 4.75 mm
thick, which has a density of 970 kg /m².
The allowable stress is 2 MPa. Two
pulley rotate in opposite directions and
the centre distance of the shafts is 750
mm. The coefficient of friction is 0.3 for
both the pulleys. Determine the width of
the belt. (10)
37. A 5 cm diameter solid shaft is welded to a
flat plate by 1 cm fillet weld. What will
be the maximum torque that the welded
joint can sustain if the permissible shear
stress in the weld material is not to
exceed 8 kN/cm2 ?
Deduce the expression for the shear stress
at the throat from the basic theory. (10)
 MD - IES CONVENTIONAL 1995-2015

2005 PAPER - II
2003 Paper – 2 44. A full journal bearing operating under a
39. Name the processes by which external steady load has the following
screw thread can be produced (both specifications : (20)
manually using tools and in machines). (l) Journal diameter: 60 mm
(10) (2) Bearing length : 60 mm
(3) Radial load on bearing: 2·8 kN
2004 Paper - 2 (4) Journal speed: 1020 rpm
40. An antifriction bearing used in a gear box (5) Radial clearance: 0·05 mm
has a specification 6108. What do the (6) Viscosity of oil: 80×10–9 N-s/mm²
numbers 6, 1 and 08 signify? (12) (7) Density of oil : 860 kg/m³
(8) Specific heat of oil: 1.76 kJ/kg-°C
41. Mention three different methods used to Using Raymonds & Boyd table given at
prevent an antifriction bearing from the end of the problem, determine
sliding axially in a shaft at the inner race (i) Sommerfeld Number
and in a bore at the outer race. (18) (ii) Power loss in friction
42. Which one of the three bearings listed (iii) Temperature rise if heat generated
below will you choose to take a heavy is entirely carried by oil
axial load on the bearing (i) self (iv) Minimum film thickness, and its
aligning ball bearing (ii) deep groove location
ball bearing (iii) Thrust bearing. Give Table - Giving Raymond’s & Boyd data
reasons for your selection. (10) for journal bearing for L/D = 1

43. A hot rolled steel shaft is subjected to a

torsional load that varies from 300 kNmm
clockwise to 100 kNmm anticlockwise as
an applied bending moment at a critical
section varies from +400 kNmm to -200
kNmm. The shaft is of uniform corss
section and no key-way is present at the
critical section. Determine the required
shaft diameter by taking factor of safety
1.5. For the material, take ultimate tensile
stress as 560 MPa, stress at yield point
420 MPa design stress is 280 MPa. Also
take the modification factor as 0.62, size
correction factor as 0.85, the load factor
for bending as 1 and the load factor for
torsion as 0.58. (40)
45. A car has a three cylinder engine which
produces maximum torque of200 N-m at
2000 rpm. The power is transmitted by a
single plate friction clutch of230 mm
outside diameter. Design dimensions of
friction surfaces. Further when the car is
engaged at a speed of 60 km/hr, calculate
the clutch slip period (time) during
engagement. (20)
Additional data as under :

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 MD - IES CONVENTIONAL 1995-2015
(i) Engine speed at beginning of
clutch engagement : 2000 rpm
(ii) Engine torque at engagement: 100
N-m
(iii) Mass of car (loaded) : 1500 kg
(iv) Wheel diameter: 710 mm
(v) Coefficient of friction: 0·3
(vi) Permissible pressure for friction
material: 0·25 N /mm²
(vii) Mass moment of inertia of engine
rotating parts, flywheel and
driving side of clutch 1·5 kg-m²
(viii) Gear reduction at differential: 4·12
(ix) Torque available at the rear
wheels: 105 N-m Uniform wear
theory may be used for the clutch
plate design.
2006 PAPER - II
46. Design and draw a cast iron flange
coupling for a mild steel shaft
transmitting 80 kW at 220 r.p.m. with the
following specifications:
Allowable shear stress in the shaft = 40
MPa Permissible angle of twist < l° in
a length of 20 diameters.
Allowable shear stress in the coupling
bolts = 30 MPa. Rigidity modulus of shaft
material = 85 GPa
Allowable shear stress for hub material =
15 MPa
You may adopt,
Width of key = 25 mm
Thickness of key = 14 mm
You may also consider that the shaft and
key are made of the same material.
Four number of bolts are to be used in the
coupling. Find out the diameter of the
shaft required and the main dimensions of
the Flanges and the Key. Adopt suitable
dimensions.
4
47. Draw a neat sketch for the Flange
coupling with the designed dimensions.
(20)
48. A centrifugal clutch with four shoes is
used to transmit 15 kW to 720 r.p.m. The
speed at which engagement begins is 80%
of full speed. The inside diameter of the
drum is 325 mm and outside diameter of
the drum is 350 mm. The radial distance
of C.G. of each shoe from the axis of
shaft is 120 mm. The radial clearance
between the shoe and the rim is 10 mm.
The pressure exerted on the shoe during
engagement is 0·1 MPa. The coefficient
of friction between shoe lining and the
drum is taken as 0·25.
Determine:
(i) Mass of each shoe.
(ii) Size of the shoe if the angle
subtended by shoe at centre is 60°.
Also design the helical spring used
in the shoes taking the safe shear
stress of spring material as 600
MPa and modulus of rigidity of
the material as 80 kN/mm2. Use
the spring index of 6. (20)
2007 Paper - 2
49. Design a flat belt drive system for the
following specifications :
Power to be transmitted = 100 kW
Pulley diameters = 0·8 m and 1 m,
respectively
Centre distance between the pulleys = 3m
Belt speed = 20 m/s
Coefficient of friction between the belt
and pulleys = 0·3
Slip = 1.2% at each pulley
Friction loss at each shaft = 5%
 MD - IES CONVENTIONAL 1995-2015
Overload capacity = 20%
Density of leather belt material = 1000
kg/m³
Safe stress for the belt = 2·5 MPa
Thickness of the belt = 12 to 16 mm
Take into account the effect of centrifugal
tension.
Find the width and the length of the belt.
Draw a schematic diagram of the belt
drive. (20)
50. A shaft ABCD is supported at one end A
and at point C. The other end D consists
of a pulley which has belt tensions in the
vertical direction. The distance AD is
1200 mm. AC distance is 800 mm. A spur
gear having pressure angle 20° is mounted
at point B which is at a distance 400 mm
from A. The diameter of pulley is 450
mm and that of the gear is 300 mm. The
gear is supplied power equal to 20 kW at
500 rpm by another gear at the top of it.
The tension on the tight side is 3 times the
tension on slack side in the belt. The
combined shock and fatigue factors for
bending moment and torsional moment
may be taken as 1·5. The tensile strength
of the material of the shaft and key is 700
MPa. Design the shaft and key for the
pulley assuming factor of safety equal to
5. Assume allowance for the key way for
stress as 0.75. (20)
2008 PAPER - II
51. Determine the size of the weld required
for static loading in the eccentrically
loaded weld as show in the figure below.
Allowable stress for the weld may be
taken as 75 N /mm 2. O the CG of the
weld area. (20)
5
2009 Paper - II
52. The screw of a car lift has 150 mm dia.
with square threads of 50 mm pitch and
lead of 100 mm. Assume 1000 N is
required for lifting of the car and thread
friction coefficient is 0.20.
(i) Compute the torques required to
rotate the screw to raise the car
and lower the car. Also compute
the overall efficiency of the screw.
(ii) What is the flaw in the above
design? (15)
53. Most of the times the rotating disc-shafts
have keys; under such conditions it cannot
be assumed that the shaft has a uniform
cross-section. For such a disc-shaft
system how will you determine the limits
of speed for instability ? (5)
2010 PAPER – II
54. Two railway coaches are coupled with the
help of two tie rods of a turn buckle with
right and left handed threads having
single-start square threads. Pitch and
mean diameter of the threads are 8 mm
and 30 mm respectively. How much
energy will be spent in bringing two
coaches closer through a distance of 320
mm against a steady load of 5.0 kN. Use
coefficient of friction in screw thread and
 MD - IES CONVENTIONAL 1995-2015
coupler nut as 0.12. Determine shear
stress on the tie rod due to above torque.
(10)
55. A flat belt drive is required to transmit 10
kW from a motor running at 1000 rpm.
The belt is 15 mm thick and has a mass
density of 0.001 gm/mm3. Permissible
tensile stress for the belt material is 2.5
N/mm2. Diameter of the driving pulley is
250 mm, whereas the speed of the driven
pulley is 367 rpm. Driving and driven
shafts are 1.25 m apart. The coefficient of
friction between belt and pulley may be
taken as 0.25. Determine the width of the
belt for safe working. ()
2011 Paper - 2
56. A hollow shaft whose ratio of internal
diameter to external diameter (k) is 0.5,
transmits 1.5 kW at 1400 rpm. At a
certain section it is also subjected to a
bending moment of 5 N.m. The shaft is to
be made from chrome-vanadium steel
having allowable shearing stress of 200
MPa. Design the shaft using the ASME
code formula for transmission shafting as
given below :
Do (outer diameter) =
Combined shock and fatigue factor for
bending moment (Cm) is 1.5.
Combined shock and fatigue factor for
torque (Ct) = 1.0. Determine the internal
and outer diameter of the shaft. (15)
57. What are common modes of failure of
rolling element bearings? (5)
6
2012 Paper - 2
59. The following particulars refer to a screw
jack shown in Figure below :
Vertical load on the screw W=20000 N
Force applied at the lever end whose
length l = 80cm
Mean radius of the screw r=2.5cm
Pitch of the screw p=1cm
Mean radius of contact surface between
swivel & head rm=4cm
Coefficient of friction between
screw thread and bearing ’ = 0.15
Coefficient of friction between the swivel
head and bearing  = 0.1
Determine :
(i) the force on the lever end required
while raising and lowering the
load.
(ii) the efficiency of the screw jack in
both cases. (12)
60. An open belt system is transmitting 10
kW power. Driving pulley is of diameter
200 mm and driven pulley is of diameter
480 mm. Centre distance between the
pulleys is 2 m. Maximum stress in belt is
not to exceed 2.2 MPa. Thickness of the
belt is 8 mm. Determine breadth and
length of the belt. Given density of belt
 MD - IES CONVENTIONAL 1995-2015
material = 950 kg/m3 Coefficient of
friction between belt and pulley = 0.3.
Driving pulley is rotating at 1000 rpm.
Neglect bending stress in belt. (20)
61. What are different types of threads used
for power transmission ? Make a simple
sketch of each. Give special features of
each thread and their applications. (10)
62. Fatigue life of a 6 x 37 wire rope of
nominal diameter of 12 mm is to be
achieved to be 0.2 billion bends. Tensile
stress designation of wire rope is 1960
MPa. How much load can be lifted
through a sheave of diameter 400 mm,
through the arrangement shown in figure.
Take ratio of bearing pressure between
rope and sheave to ultimate strength of
rope = 0.0024. (10)
2013 Paper – 2
63. A 100 mm steel drive shaft transmitting
150 kW at 300 r.p.m. has to be connected
to a machine having same diameter shaft
with a cast iron (CI) unprotected flange
coupling. The permissible shear stress for
the shaft, bolt and key are 50 MPa. The
bearing stress for bolt and key are 50 MPa
and shear stress for CI is 8 MPa. The
basic dimensions of the coupling may be
assumed as per the standard. Design the
7
coupling and verify all the major
dimensions for strength. (20)
64. A full journal bearing has a journal
diameter D of 25 mm, with a unilateral
tolerance of - 0.038 mm. The bushing
bore has a diameter B of 25.038 mm and a
unilateral tolerance of 0.075 mm. The l/D
ratio is unity. The load is 1.1 kN and the
journal runs at 18.33 r.p.s. The average
viscosity is 55.2 mPa-s.
Minimum film thickness variable is 0.58
and coefficient of friction variable is 4.0.
Find
(a) Sommerfeld number
(b) minimum film thickness
(c) frictional torque. (10)
2014 Paper - 2
67. A drive shaft of 40 mm diameter
transmitting 25 kW at 300 rpm is
connected to a gear by a flat key of width
22 mm and thickness 14 mm. It is made
of steel having 300 MPa yield stress.
Determine the length of the key to
withstand shear. use a factor of safety 2.
(4)
68. A plate clutch has a single surface with an
outside diameter of 250 mm and inside
diameter of 100 mm with a coefficient of
friction 0.4. Find the required axial force
to develop a maximum pressure of 0.65
MPa. Under this pressure, find the torque
capacity of the clutch. (4)
69. A power screw is made with Acme
threads 34 mm-6 mm, single start to lift
and lower a load of 10 kN. The screw and
nut are well lubricated. Sliding friction is
 MD - IES CONVENTIONAL 1995-2015

0.15 and rolling friction is 0.02. Take
semi thread angle as 14.50. Determine:
(10)
(i) Raising Torque
(ii) Lowering Torque
(iii) Efficiency of the power
screw
70. Design a gib and cotter joint for two rods
of square cross section transmitting an
axial tensile load of 40 kN. The gib, cotter
and rods are made of same material
having allowable tensile strength of 120
MPa and shear strength of 60 MPa and
crushing strength of 160 MPa. Assume
the thickness of cotter as one-third of side
of the square cross section. (10)
73. A 5 cm dia. solid shaft is welded to a flat
plate by 1 cm fillet weld. What will be the
max. torque that the welded joint can
sustain if the permissible shear stress in
the weld material is not to exceed 8
kN/cm2. Deduce the expression for the
shear stress at the throat from the basic
theory. (4)
74. A hydrostatic conical bearing is shown in
the figure. Show that the load carrying
capacity of the bearing is given by

71. A 3600 hydrodynamic bearing has a and the flow requirement is given by,
journal diameter of 60 mm and length 60
mm. It is running at a speed of 1200 rpm.
The radial clearance is 0.04 mm and
minimum oil thickness is 0.008 mm. (15)
Sommerfeld number is 0.0446. Find the
viscosity of the oil suitable for the 75. Explain the concept of real and apparent
bearing. (10) areas of contact. Write the formula for
each. (10)
2015
72. A single plate clutch is designed to
transmit 10 kW power at 2000 rpm. The
equivalent mass and radius of gyration of
the input shaft are 20 kg and 75 mm
respectively. The equivalent mass and
radius of gyration of the output shaft are
35 kg and 125 mm respectively.
Calculate:
The time required to bring the output
shaft to the rated speed from rest. (4)