Addis Ababa Science and Technology University

Electromechanical Engineering
Design Machine Element I; Worksheet

1. An engine cylinder is 300 mm in diameter and the steam pressure is 0.7 N/mm2. If the cylinder head is held by 12
studs, Determine the nominal diameter of the stud if dc = 0.8d. Assume safe tensile stress as 28 MPa. [Ans. M24]
2. An electric motor weighing 10 KN is lifted by means of an eye bolt as shown in fig 2.1. The eye bolt is screwed
into the frame of the motor. It is made of plain carbon 30C8 steel with the yield strength of Syt = 400 N/mm2 and the
factor of safety is 6. Determine the nominal diameter of the eye bolt if dc = 0.8d. [Ans. M20]
3. Two plates are fastened by means of two bolts as shown fig 2. The bolts are made of plain carbon steel 30C8 (Syt =
400 N/mm2) and the factor of safety is 5. Determine the nominal diameter of the bolt having coarse threads if dc =
0.8d and P = 5 KN. [Ans. M 9]

Figure 2.
Figure 1.
4. Two plates, each 5 mm thick, are connected by means of four rivets as shown in fig. 3. The permissible stresses for
rivets and plates in tension, shear and compression are 80, 60 and 120 N/mm2 respectively. Calculate:
i. Diameter of the rivets
ii. Width of the plate
iii. Efficiency of joint

[Ans. (i) 8.92 mm or 9 mm (ii) 46.5 mm or 50 mm (iii) 76.34%]

5. Two plates, each 15mm thick and carrying an axial load of 175 KN, are connected by means of double-strap butt
joint as shown in figure 4. Assume that rivets in double shear are 1.875 times stronger than in single shear. The
permissible stresses for rivets and plates in tension, shear and compression are 80, 60 and 120 N/mm2 respectively.
Calculate:
i. Diameter of the rivets
ii. Width of the plate
Assume the above values, calculate:
iii. Strength of the joint if failure is to occur along the section-AA
iv. Strength of the joint if failure is to occur along the section-BB
v. Strength of the joint if failure is to occur along the section-CC
vi. Strength of the joint if failure is to occur due to shearing of rivets

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 Addis Ababa Science and Technology University
Electromechanical Engineering
Design Machine Element I; Worksheet

vii. Strength of the joint if failure is to occur due to crushing of rivets

viii. Strength of solid plate
ix. Efficiency of the joint

Figure 3 Figure 4

6. A bracket as shown in the fig 5 is welded a plate. The welds have the same size and the permissible force per mm
of the weld-length is 1 KN. Calculate the length l1 and l2. [Ans. 40 mm and 80 mm]
7. A steel plate 80 mm wide and 10 mm thick is joined to another steel plate by means of a single transverse and double
parallel fillet welds as shown in fig. 6. The strength of the welded joint should be equal to the strength of the plates
to be joined. The permissible tensile and shear stresses for the weld material and plates are 100 and 70 N/mm 2
respectively. Find the length of each parallel fillet weld. [Ans. 23.68mm]
8. A gas tank consists of a cylindrical shell 2.5 m inner diameter. It is enclosed by hemispherical shell by means of
butt welded joint as shown in fig 7. Thickness of the cylindrical shell as well as the hemispherical cover is 12 mm.
determine the allowable internal pressure to which the tank may be subjected, if the permissible tensile strength of
the weld is 85 N/mm2. [Ans. 1.632 N/mm2]

Figure 6
Figure 7

Figure 5.

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 Addis Ababa Science and Technology University
Electromechanical Engineering
Design Machine Element I; Worksheet

9. The cross-section of flat key for a 40 mm diameter shaft is 22 × 14 mm. The power transmitted by the shaft to the
hub is 25 kW at 300 rpm. The key is made of steel (Syc = Syt = 300 N/mm2) and the factor of safety is 2.8. Determine
the length of the key. Assume (Ssy = 0.577 Syt). [Ans. 53.05 mm]
10. It is required to design a square key for fixing a pulley on the shaft, which is 50 mm in diameter. The pulley transmits
10 kW power at 200 rpm to the shaft. The key is made of steel 45C8 (Syc = Syt = 380 N/mm2) and the factor of safety
is 3. Determine the dimensions of the key. Assume (Ssy = 0.577 Syt). [Ans.12.5 ×12.5 × 25 mm]
11. A flat key is used to connect a pulley to a 45 mm diameter shaft. The standard cross section of the key is 14 × 9
mm. The key is made of commercial steel (Syc = Syt = 230 N/mm2) and factor of safety is 3. Determine the length
of the key on the basis of shear and compression considerations, if 15 kW power at 360 rpm is transmitted through
the keyed joint. Assume (Ssy = 0.5 Syt). [Ans. 32.95 and 51.26 mm]
12. It is required to design a helical compression spring subjected to a force of 500 N. the deflection of the spring
corresponding to this force is approximately 20 mm. the spring index should be 6. The spring is made of cold-drawn
steel wire material with ultimate tensile strength and modulus of rigidity 1000 and G = 81370 N/mm2 respectively.
The permissible shear stress for the spring wire can be taken as 50% of the ultimate tensile strength. Assume a gap
of 1 mm between adjacent coils under maximum load condition. The spring has square and ground ends. Design
the spring and calculate:
i. Wire diameter, [Ans. 4.37 or 5 mm]
ii. Mean coil diameter, [Ans. 30 mm]
iii. Number of active coils, [Ans. 10]
iv. Total number of coils, [Ans. 12]
v. Free length of the spring, [Ans. 92.24 mm]
vi. Pitch of the coils, [Ans. 8.39 mm]

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