LOYOLA-ICAM College of Engineering and Technology

Loyola Campus, Chennai - 600 034.

DEPARTMENT OF MECHANICAL ENGINEERING

Year/Semester: III / V Max. Marks: 100

Date: 22.12.2021. Time: 3 Hrs
MODEL EXAM
ME8593 DESIGN OF MACHINE ELEMENTS
CO1 Explain the influence of steady and variable stresses in machine component design.
CO2 Apply the concepts of design to shafts, keys and couplings.
CO3 Apply the concepts of design to temporary and permanent joints and design energy absorbing members

CO4 Apply the concepts of design to connecting rod, crank shaft and bearings.

CO5 Design machine systems by inferring standard catalogue and data book, for real world applications and societal needs.
K1: Remember K2: Understand K3: Apply K4: Analyze K5: Evaluate K6: Create

PART-A (Answer all the Questions) (10x2=20)

1. Brief about Soderberg and Goodman lines. [CO1/K1]
2. Give some methods of reducing stress concentration. [CO1/K2]
3. Under what circumstances are hollow shaft preferred over solid shafts? [CO2/K2]
4. Differentiate between rigid and flexible couplings. [CO2/K2]
5. What do you understand by the term efficiency of a riveted joint? [CO3/K2]
6. List out the different types of cotter joints? [CO3/K1]
7. What is nipping in a leaf spring? Discuss its role. [CO4/K2]
8. Describe why flywheels are used in punching machines? [CO4/K1]
9. Define static capacity of bearing. [CO5/K1]
10. How do you express the life of a bearing? What is an average or median life [CO5/K2]

PART – B (Answer in detail) (5 x 13 = 65)

11.a i) A shaft which has a diameter of 30mm is subjected to an axial tension load of 15KN and torque of
400Nm. In addition to these, there is a bending moment of 300Nm on the shaft. The shaft is made of steel
having the properties of σu=780 MPa and σy =600Mpa (Ref the Figure)

Neglecting the column action, determine the FOS.

i) by using distortion energy theory of failure.
ii) by using maximum shear stress theory of failure [CO1/K3]
(or)
11.b) A 40 mm diameter shaft is made from carbon steel having ultimate tensile strength of 600 MPa. It
is subjected to a torque which fluctuated between 1500 Nm to –900 Nm. Using Soderberg method,
calculate the FOS. Assume suitable values for any other data needed (13) [CO1/K3]

12.a) A section of commercial shafting 2m long between bearings carries a 1000 N pulley at its
mid-point, as shown in Figure. The pulley is keyed to the shaft and receives 30 KW at 150 rev/min
which is transmitted to a flexible coupling just outside the right bearings. The belt drive is
horizontal and some of the belt tensions is 8000N, Assume Kt = Kb = 1.5. Calculate the necessary
shaft diameter and determine the angle of twist between bearings. G=80 GN/m3.
 [CO2/K3]
(or)
12. b) Design a cast iron protective type flange coupling to transmit 15kW at 900 rpm from an
electric motor to a compressor. The service factor may be assumed s 1.35. The following
permissible stresses may be used. Shear stress for shaft, bolt and key material=40MPa, crushing
stress for bolt and key=80 MPa, Shear stress for cast iron=8 MPa. [CO2/K3]

13.a) A welded connection as shown in fig 3.5. below is subjected to an eccentric force of 7.5KN.
Estimate the size of welds if the permissible shear stress for the weld is 100 N/mm2
.
Assume static conditions.

[CO3/K3]
(or)
13. b) For supporting the travelling crane in a workshop, the brackets are fixed on steel columns as
shown in Fig. The maximum load that comes on the bracket is 12 kN acting vertically at a distance of
400 mm from the face of the column. The vertical face of the bracket is secured to a column by four
bolts, in two rows (two in each row) at a distance of 50 mm from the lower edge of the bracket.
Determine the size of the bolts if the permissible value of the tensile stress for the bolt material is 84
MPa. Also find the cross-section of the arm of the bracket which is rectangular. [CO3/K3]

14.a) At the bottom of a mine shaft, a group of 10 identical close coiled helical springs are set in parallel
to absorb. The shock caused by the falling of the cage in case of a failure. the loaded cage weighs
75KN, while the counter weight has a weight of 15KN. If the loaded cage falls through a height f 50
meters from rest, find the maximum stress induced in each spring if it is made of 50mm diameter steel
rod. The spring index is 6 and the number of active turn in each spring is 20. Modulus of rigidity G=
80KN.mm2 [CO4/K3]
(or)
14. b) Design a leaf spring for the following specifications: Total load = 140 kN ; Number of springs
supporting the load = 4 ; Maximum number of leaves = 10; Span of the spring = 1000 mm ; Permissible
deflection = 80 mm. Take Young’s modulus, E = 200 kN/mm2 and allowable stress in spring material
as 600 MPa. [CO4/K3]
15. a) The load on the journal bearing is 150kN due to turbine shaft of 300mm diameter running at
1800 rpm. Determine the following. Length of the bearing if the allowable bearing pressure is
1.6N/mm2 and amount of heat to be removed by the lubricant per minute if the bearing temperature is
60ºC and viscosity of the oil at 60ºC is 0.02 kg/m.s and the bearing clearance is 0.25 mm. [CO5/K3]
(or)
15. b) Select a single row deep groove ball bearing for a radial load of 4000N and an axial load of
5000N, operating at a speed of 1600 rpm for an average life of 5 year at 10hours per day. Assume
uniform and steady load. [CO5/K3]

PART C (1 x 15 = 15 marks)
16. a) The intercepted areas between the output torque curve and the mean resistance line of a turning
moment diagram for a multi-cylinder engine, takes in order from one end are as follows:
-35, +410, -285, +325, -335, +260,-365,+285,-260 mm2.
The diagram has been drawn to a scale of 1 mm = 70N-m and 1mm = 4.5°. The engine speed is 900
RPM. and the fluctuation in speed is not to exceed 2% of the mean speed. Find the mass and cross-
section of the flywheel rim having 650 mm mean diameter. The density of the material of the flywheel
may be taken as 7200 kg/m3. The rim is rectangular with the width 2 times the thickness, Neglect effect
of arm, etc. [CO4/K3]
(or)
b) A shaft made of steel receives 7.5 kW power at 1500 rpm. A pulley mounted on the shaft as shown
in fig. has ratio of belt tension 4. The gear forces are follows Ft = 1590N; Fr = 580 N Design the shaft
diameter by maximum shear stress theory. The shaft material has the following properties. Ultimate
tensile strength = 720 MPa; Yield strength = 380 MPa; Factor of safety = 1.5

[CO2/K3]