Seat No.: ________ Enrolment No.

___________

GUJARAT TECHNOLOGICAL UNIVERSITY

BE - SEMESTER–VII (NEW) EXAMINATION – WINTER 2021
Subject Code:3171925 Date:29/12/2021
Subject Name:Advanced Machine Design
Time:10:30 AM TO 01:00 PM Total Marks: 70
Instructions:
1. Attempt all questions.
2. Make suitable assumptions wherever necessary.
3. Figures to the right indicate full marks.
4. Simple and non-programmable scientific calculators are allowed.

MARKS
Q.1 (a) Using Metallurgical compatibility chart given in Figure 1, Write three pairs of 03
metals which ensures minimum adhesive wear.
(b) Explain any two modes of the crack displacement with sketch. 04
(c) A spherical pressure vessel having internal diameter 3.048m and the thickness 07
25.4mm, is to be made of steel. The non-destructive testing technique available
can detect through the thickness crack of minimum size 2.54mm. Three grades
of steel are available. Using both the ‘conventional design approach’ and
‘fracture mechanics approach’, select a grade for maximum permissible internal
pressure.

Plain strain fracture

Yield stress
Grade toughness KIC
σϒ (Mpa)
(Mpa/m)
200 1510 113.25
250 1720 95.35
300 2040 66.46

Q.2 (a) Discuss three ways for designing to avoid surface failure. 03
(b) A ball thrust bearing with 7 spherical balls each of 10 mm diameter is loaded 04
axially across its races through the balls. Races are flat. All parts are hardened
steel. The axial load is 21.5 lb per ball. Calculate the size of the contact patch on
a race.
Assume the 7 balls share the load equally. The rotational speed is sufficiently
slow that this can be considered a static loading problem.

(c) Using example given in Figure 2, summarize use of “Rain flow cycle counting 07
method” for cumulative damage.
OR
(c) The stress-time pattern shown in Figure 3(a) is to be repeated in blocks. Using 07
the rain flow cycle counting method and the S-N curve of Figure 3(b), estimate
the time in hours of testing required to produce failure.
Q.3 (a) Discuss influence of any three factors on S-N behavior of any machine element. 03

1
 (b) Derive the following condition for “failure is predicted to occur if (FIPTOI)”. 04
𝑛
𝑛𝑗
∑ ≥1
𝑁𝑗
𝑗=1

(c) A wrought carbon-steel alloy is known to have the static properties Sut = 76,000 07
psi, Sy = 42,000 psi, and e (2 inches) = 18 percent, but fatigue properties cannot
be located for the material. It is necessary to quickly estimate the fatigue
properties for the preliminary design of a machine part for which the fluctuating
loads will induce a stress spectrum with cyclic amplitudes in both the finite-life
range and the infinite-life range. Estimate the “mean S-N curve” for basic small-
polished-specimen of this material.

OR
Q.3 (a) Discuss the cumulative damage concept for mean zero stress with S-N diagram. 03

(b) Discuss the various stress-time patterns with diagram. 04

(c) An axially loaded straight cylindrical bar of diameter d = 12.5 mm is to be made 07
of 2024- T4 aluminum with ultimate strength of Sut = 469 MPa, yield strength Syp
= 331 MPa, and fatigue properties shown in Figure 4. The bar is to be subjected
to a completely reversed axial force of 27 kN, and must last for at least 107 cycles.
Predict weather the failure would occur or not by considering fatigue as a
governing failure mode.

Q.4 (a) Explain the need of creep testing in design of machine element. 03
(b) Using Sines method for fluctuating simple multiaxial stresses, create an equation 04
for equivalent mean stress.
(c) A power transmission shaft of solid cylindrical shape is to be made of 1020 hot- 07
rolled steel with Su = 65,000 psi, Syp = 43,000 psi, e = 36 percent elongation in 2
in, and fatigue properties are same as 1020 steel. The shaft is to transmit 85
horsepower at a rotational speed of n = 1800 rpm, with no fluctuations in torque
or speed. At the critical location, mid-span between bearings, the rotation shaft is
also subjected to a pure bending moment of 1500 in-lb, fixed in a vertical plane
by virtue of a system of symmetrical external forces on the shaft. Calculate the
value of multiaxial state of cyclic stress (σeq-CR) to predict fatigue failure
occurrence.
OR
Q.4 (a) Write the three effects of creep on life of machine element. 03
(b) Using Von-Mises method for fluctuating simple multiaxial stresses, create an 04
equation for equivalent mean stress.
(c) A torsionally oscillating 12 inch long shaft of 1.25 inch diameter has a 0.25 inch 07
diametral hole all the way through it. By the way the shaft is loaded, it is subjected
to a released torsional moment of 8300 in-lb, and an in-phase released cyclic
bending moment, in the plane of the through-hole axis, of 3700 in-lb. If the shaft
is made of 4340 steel with Su = 150,000 psi, Syp = 120,000 psi and e = 15 percent
in 2 inch, Calculate alternating and mean component stresses. (Assume that the
critical point for bending and torsion coincide.)
Q.5 (a) Write three points of discussion on time–temperature parameters to estimates life 03
of machine components using graph given in Figure 5.

2
 (b) An engineering component made of the heat-resisting Fe-Cr-Ni-Co alloy S-590 04
is subjected in service to a static stress of 200MPa at a temperature of 600◦C.
Using Sherby-Dorn Parameter, estimate creep–rupture life in days. Refer Figure
6.
(c) Explain Split housing and Non-Split housings with neat sketch. 07
OR
Q.5 (a) Draw creep curve “strain versus time” and write three points of discussion on. 03

(b) For the rheological models (a) to (d), given in Figure 7, draw strain vs time curve 04
and write strain–time equation for each. Assume applied stress is constant.

(c) Design and draw the housing for the spur gear train with following data. 07
Centre distance (A) is 200 mm, Bore of housings (D) for selected ball bearings
of shafts is 50 mm, and their nominal diameters are the same like outside
diameters of the bearings. Face width of the pinion is 20 mm. Dimensions of a
flange (k), distance from the wall to the bolt axis (c), hole for the bolt (d0) and a
spot face (D0) can be selected from following table.

3
 W Mo Cr Co Ni Fe Nb Pt Zr Ti Cu Au Ag Al Zn
Zn ① ② ① ① ① ① ③ ① ③ ② ① ① ① ① ⓪
Al ① ② ① ② ① ① ① ② ② ① ① ① ① ⓪
Ag ④ ③ ④ ④ ④ ④ ③ ① ① ① ② ① ⓪
Au ① ① ① ① ① ① ① ① ① ② ① ⓪
Cu ③ ④ ④ ① ① ① ③ ① ① ② ⓪
Ti ① ① ① ② ① ① ① ① ① ⓪
Zr ② ① ② ① ② ③ ① ② ⓪
Pt ① ① ① ① ① ① ① ⓪
Nb ① ① ① ① ① ① ⓪
Fe ① ① ① ① ① ⓪
Ni ① ① ① ① ⓪ ④ Metallurgically incompatible
Co ① ① ① ⓪ ③ Partially incompatible
Cr ① ① ⓪ ② Partially compatible
Mo ① ⓪ ① Metallurgically compatible
W ⓪ ⓪ Identical metals

Figure 1. Metallurgical compatibility chart (Que. 1 (a))

Figure 2. Example of rain flow cycle counting method (Que. 2(c))

4
Figure 3(a) Stress-time pattern (Que. 2(c) OR)

Figure 3(b) S-N Curve (Que. 2(c) OR)

5
 Figure 4 (Que. 3 (C) OR)

Figure 5. Stress vs Strain (Que. 5 (a))

6
Figure 6. Stress vs Sherby-Dorn Parameter (Que. 5 (b))

Figure 7. Rheological models (Que. 5 (b) OR)

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