Shivaji University , Kolhapur

Question Bank For Mar 2022 ( Summer ) Examination

Subject Code : 80756 Subject Name : Machine Design - I

Common subject code PCC-ME304

1. Describe various steps involved in design of a machine element?

2. Select suitable materials for the following parts stating the special property which
makes it most suitable for use in manufacturing:
1. Turbine blade, 2. Bush bearing, 3. Dies, 4. Carburetor body, 5. Keys (used for
fastening), 6. Cams,
3. Suggest suitable materials for the following parts stating the special property which
makes it more suitable for use in manufacturing:
1. Diesel engine crankshaft ; 2. Automobile tyres ; 3. Roller bearings ; 4. High
pressure steam pipes ; 5. Stay bar of boilers ; 6. Worm and worm gear
4. Suggest with justification the suitable material for the following:
Boiler Shell ii) Valve spring iii) Cutting tools
5. Suggest with justification the suitable material for the following;
i)Side Stand Spring of Bike ii) Lathe Tail-Stock iii) Water Bottle
6. Summarize the guidelines for the selection of quantitative values of factor of safety
7. What are the important theories of elastic failures?
8. State and explain distortion energy theory of failure
9. State and explain maximum principal stress theory of failure.
10. State and explain maximum shear stress theory of failure
11. Draw neat sketch of a knuckle joint and explain the design procedure
12. What are the advantages of square threads over trapezoidal threads?
13. Discuss the design of a bell-crank lever.
14. What is recirculating ball screw? Explain with neat sketch.

15. A 50 kN capacity screw jack consists of a square-threaded steel screw meshing with
bronze nut. The nominal diameter is 60 mm and the pitch is 9 mm. The permissible
bearing pressure at the threads is 10 N/mm2.
 Calculate:
(i) the length of the nut; and
(ii) the transverse shear stress in the nut.
16. A double-threaded power screw, with ISO metric trapezoidal threads is used to raise a
load of 300 kN. The nominal diameter is 100 mm and the pitch is 12 mm. The
coefficient of friction at the screw threads is 0.15. Neglecting collar friction calculate
(i) torque required to raise the load;
(ii) torque required to lower the load; and
(iii) efficiency of the screw
17. Two rods are connected by means of a knuckle joint. The axial force P acting on the
rods is 25 kN. The rods and the pin are made of plain carbon steel 45C8 (Syt = 380
N/mm2) and the factor of safety is 2.5. The yield strength in shear is 57.7% of the yield
strength in tension. Calculate: (i) the diameter of the rods, and (ii) the diameter of the pin.
18. A bell crank lever is subjected to a force of 7.5 kN at the short arm end. The lengths of
the short and long arms are 100 and 500 mm respectively. The arms are at right
angles to each other. The lever and the pins are made of steel FeE 300 (Syt = 300
N/mm2) and the factor of safety is 5. The permissible bearing pressure on the pin is
10 N/mm2. The lever has a rectangular cross-section and the ratio of width to
thickness is 4 : 1. The length to diameter ratio of the fulcrum pin is 1.5 : 1.
Calculate:
(i) the diameter and the length of the fulcrum pin
(ii) the shear stress in the pin
(iii) the dimensions of the boss of the lever at the fulcrum pin
(iv) the dimensions of the cross-section of the lever
19. A power screw having double start square threads of 25 mm- nominal diameteter and
5 mm pitch is acted upon by an axial load of 10 kN. The outer and inner diameters of
screw collar are 50 mm and 20 mm respectively. The coefficient of thread friction and
collar friction mav be assumed as 0.2 and 0.15 respectively. The screw rotates at 12 rpm.
Assuming uniform wear condition at the collar and allowable thread bearing pressure of
5.8 N/mm2. Find
i) The torque required to rotate the screw. ii) Stress in the screw
ii) Number of threads of nut in engagement with screw
20. Explain the design procedure for a turn-buckle with the help of neat sketch.
21. What types of stresses are induced in shafts? How the shaft is designed based on rigidity?
22. Demonstrate the use of ASME code for shaft design with suitable example.
23. What are various types of keys? Compare stresses in woodruff key with flat key?
24. Discuss the design procedure for square key
25. A splined connection with the following particulars is used for a gear and shaft assembly
in a gear box. The power to be transmitted is 20kW at 240 r.p.m. The bearing pressure on
the splines is limited to 6.5MPa during sliding. The coefficient of fi.iction is 0.1
Major diameter: 60mm Minor diameter: 54 mm Number of splines: l0
Determine
(i) The length of gearhub
ii) The force required to shift the gear.
26. Design a cast iron protective type flange coupling to transmit 15 kW at 900 r.p.m. from
an electric motor to a compressor. The service factor may be assumed as 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
Draw a neat sketch of the coupling.
27. The layout of an intermediate shaft of a gear box supporting two spur gears B and
C is shown in Fig.The shaft is mounted on two bearings A and D. The pitch circle
diameters of gears B and C are 900 and 600 mm respectively. The material of the shaft is
steel FeE 580 (Sut = 770 and Syt = 580 N/mm2). The factors kb and kt of ASME code
are 1.5 and 2.0 respectively. Determine the shaft diameter using the ASME code. Assume
that the gears are connected to the shaft by means of keys.

28. A transmission shaft supporting a helical gear B and an overhung bevel gear D is
shown in Fig.. The shaft is mounted on two bearings, A and C. The pitch circle diameter
of the helical gear is 450 mm and the diameter of the bevel gear at the forces is 450 mm.
 Power is transmitted from the helical gear to the bevel gear. The gears are keyed to the
shaft. The material of the shaft is steel 45C8 (Sut = 600 and Syt = 380 N/mm2). The
factors kb and kt of ASME code are 2.0 and 1.5 respectively. Determine the shaft
diameter using the ASME code.

29. Design a rigid type of flange coupling to connect two shafts. The input shaft transmits 7
kW power at 800 rpm. to the output shaft through a coupling' Assume that design torque
is 1.5 times the rated torque. Given: material for shaft -- 40C8 (Syt= 380 N/mm2, factor
of safety=2.5); Material For key 30C8 (Syt= 400 N/mm2,Factor of safety =2.5), material
for flange FG 200 (Sut = 200N/mm2, factor of safety=6 based on ultimate strength)

30. An intermediate shaft of a gearbox, supporting two spur gears A and B and mounted
between two bearings C1 and C2, is shown in Fig. The pitch circle diameters of gears A
and B are 500 and 250 mm respectively. The shaft is made of alloy steel 20MnCr5. (Sut
= 620 and Syt = 480 N/mm2). The factors kb and kt of the ASME code are 2 and 1.5
respectively. The gears are keyed to the shaft. Determine the shaft
diameter using the ASME code.
31. State the advantages and disadvantages of welded joints over bolted joints.

32. A bracket is welded to the vertical plate by means of two fillet welds as shown in
figure.Determine the size of the weld, if the permissible shear stress is limited to 70
N/mm2.

33. Describe the design procedure of the bolts subjected to eccentric loading acting
perpendicular to the axis of bolts.

34. A steel plate subjected to a force of 3 KN and fixed to a vertical channel by means of four
identical bolt is shown in figure. The bolts are made of plain carbon steel 45C8 with yield
strength of 380 N/mm2.Determine the diameter of the bolt if the factor of safety is 2.
35. Describe the design procedure of the bolted joint subjected to eccentric loading in plane
containing bolts.

36. A rectangular steel plate is welded as a cantilever to a column and supports a single
concentrated load of 60 KN as shown in figure. Determine the size of the weld if the
permissible shear stress is limited to 145 N/mm2 .

37. What are the advantages of welded joints?

38. A weldedconnection as shown in the figure is subjected to eccentric load of 60 KN in the

plane of the weld. Determine the size of the weld, if the permissible shear stress is limited
to 100 N/mm2.Assume static condition.

39. What do you understand by the term riveted joint? Explain the necessity of such joints.

40. A wall bracket is attached to the wall by means of four identical bolts, two at A and two
at B , as shown in figure. Assuming that the bracket is held against the wall and
prevented from tipping about the point C by all four bolts and using an allowable tensile
stress in the bolts as 35 N/mm2, determine the size of the bolts on the basis of maximum
principal stress theory.
41. What are the stresses induced in helical spring of circular cross section? Explain with
neat sketch.

42. Design a helical compression spring for a maximum load of 1000 N for a deflection of 25
mm, using the value of spring index as 5. The maximum permissible shear stress for
spring wire is 420 N/mm2 and modulus of rigidity is 84 KN/mm2 . Also draw neat sketch
of the spring. Takewhals factor as

K=(4C-1/4C+4)+(0.615/C)

The std wire gauge (SWG) number and corresponding diameter of spring wire is given in
following table,

SWG 1 2 3 4 5

Diameter 7.620 7.010 6.401 5.893 5.385

43. What are the various types of spring used in practice? Explain one application of each
type.

44. Design a close coiled helical compression spring for a service load ranging from 2245 N
to 2745 N. The axial deflection of the spring is 6 mm, using the value of spring index as
5. The maximum permissible shear stress for spring wire is 420 N/mm2 and modulus of
rigidity is 84 KN/mm2 . Also draw neat sketch of the spring. Take whals factor assume
square and ground ends for a coil.

The std wire gauge (SWG) number and corresponding diameter of spring wire is given in
following table,

SWG 6/0 5/0 4/0 3/0 2/0

 Diameter 11.785 10.973 10.160 9.490 8.839

45. Explain with neat sketch different styles of ends of helical compression spring.Also give
number of active turns for each.

46. A helical spring is made from wire of 6 mm diameter andhas outside diameter of 75
mm.If the permissible shear stress is 350 MPa and modulus of rigidity is 84 KN/mm2 .
Find the axial load which the spring can carry and the deflection per active turns.

47. Classify the spring and explain the various terms with the help of neat sketch in case
helical compression spring.

48. A helical compression spring is used in the spring balance to measure the weights. One
end of spring is attached to thr rigid support while the other end which is free carries the
weights to be measured. The maximum weight attached to the spring balance is 1500 N
and the length of the scale should be approximately 100 mm , the spring index can be
taken as 6. The spring is made of oil hardened and tempered steel wire with ultimate
tensile strength is 1360 N/mm2 and modulus of rigidity is 84 KN/mm2 .The permissible
shear stress shouldtaken as 50% of ultimate tensile strength .Design the spring and
calculate,

i) wire diameter ii) mean coil diameter iii) number of active coils iv) spring rate

49. Derive an expression for deflection of helical compression spring of circular wire.

50. Design a close coiled helical compression spring for a service load ranging from 2150 N
to 2650 N. The axial deflectionof the spring is 6 mm, using the value of spring index as 5.
The maximum permissible shear stress for spring wire is 420 N/mm2 and modulus of
rigidity is 84 KN/mm2 . Also draw neat sketch of the spring. Assume square and ground
ends for a coil.

The std wire gauge (SWG) number and corresponding diameter of spring wire is given in
following table,

SWG 4/0 3/0 2/0 0 1

Diameter 10.160 9.490 8.839 8.229 7.620

51. Give in steps the procedure for selection V-belt from manufacturer’s catalogue.

52. It is required to select a flat belt drive to connect two transmission shafts rotating at 800
rpm and 400 rpm respectively. The center to center distance between the shafts is
approximately is 3 m and the belt drive is open type.The power transmitted by the belt is
30 Kw and the load correction factor is 1.3.The belt should operate at a velocity between
17.8 to 22.90 m/s. The power transmitting capacity of belt per mm width per ply at 1800
arc of contact and at a belt velocity of 5.08 m/s is 0.0147 Kw. Select preferred pulley
diameters and specify the belt.

(Reference tables will be provided)

53. Give in steps the procedure to design of a flatbelt pulley.

54. A V-belt drive is required for a 15 Kw, 1440 rpm electric motor which drives a
centrifugal pump running at 360 rpm for a service of 24 hrs per day. For space
consideration, the center distance should be approximately 1 m .Determine,

i) belt specification ii) number of belts iii) correct center distance iv) pulley diameters.

(Reference tables will be provided)

55. Give in steps the procedure for selection Flat-belt from manufacturer’s catalogue.

56. A V-belt drive is required for a 20 Kw, 1440 rpm electric motor which drives a
compressor running at 480 rpm for a service of 15 hrs per day. For space consideration,
the center distance should be approximately 1.2 m. Determine,

i) belt specification ii) number of belts iii) correct center distance iv) pulley diameters.

(Reference tables will be provided)

57. State the advantages and disadvantages of V-belt drive over Flat-belt drive.

58. It is required to select a flat belt drive to connect two transmission shafts rotating at 360
rpm which is driven by 10 Kw, 1440 rpm motor. The center to center distance between
the shafts is approximately is 2 m and the belt drive is open type. The load correction
factor is 1.2.The belt should operate at a velocity between 17.8 to 22.90 m/s. The power
transmitting capacity of belt per mm width per ply at 1800 arc of contact and at a belt
velocity of 5.08 m/s is 0.0118 Kw. Select preferred pulley diameters and specify the belt.

( Reference tables will be provided)

59. Derive an expression for length of an open belt.

60. A belt pulley made of grey cast iron FG 150 has four arms of elliptical cross section in
which the major axis is the twice the minor axis. The tensions on tight side and slack side
of the belt are 759 N and 250 N respectively. The mean diameter of the pulley is 300 mm,
while the hub diameter is 60 mm.Assume that the half the no. of arms are transmit the
torque at any time. The factor of safety is 5. Determine the dimensions of the cross
sections of the pulley arm near the hub.