Important Short Questions DYNAMICS AND DESIGN OF MACHINERY

MET304 : DYNAMICS AND DESIGN OF MACHINERY
SHORT QUESTIONS
Module 1
1. Define D’Alembert’s principle.

D’Alembert’s principle states that when a system (body) is in dynamic equilibrium, the
vector sum of all the external forces and inertia forces acting upon a system of rigid
bodies is zero.
The vector sum of all the external moments and inertia torques acting upon a system of
rigid bodies is also separately zero.
ΣF + FI = 0 ; and ΣT + TI = 0.
2. What do you mean by equivalent dynamic system?
The motion of connecting rod is not linear. It is difficult to find its inertia. Therefore the
inertia is taken into account by considering the mass of connecting rod into two parts
acting at two points. The system in which the entire mass of the body is replaced by two
masses placed at fixed distance apart is called equivalent dynamic system.
Conditions to be satisfied by the system to be dynamically equivalent are:
(a) Sum of the two masses must be equal to the total mass of the body.
(b) Centre of gravities of the two masses must coincide with that of the body.
(c) Sum of the mass moments of inertia of the masses about their centre of gravity must
be equal to the mass moment of inertia of the body.
Prepared by Maneesh .M
Department of Mechanical Engineering, UKFCET Page 1
Let m1 and m2 be the two masses which form equivalent dynamic system (kg) .Let l1 be
the distance of mass m1 from G in (m) Let l2 be the distance of mass m2 from G in (m) on
the other side. Let L be the total distance between the masses m1and m2
The conditions are
(a) m1+ m2 = m
(b) m1 l1 = m2 l2
(c) m1 l1 2 + m2 l2 2 = m k2
(d) From the above conditions, we get l1 l2 = k2
3. Draw the turning moment diagram of a single cylinder double acting

steam engine.
The turning moment diagram (also known as crankeffort diagram) is the graphical
representation of the turning moment or crank-effort for various positions of the crank. It is
plotted on cartesian co-ordinates, in which the turning moment is taken as the ordinate and
crank angle as abscissa
Since the work done is the product of the turning moment and the angle turned, therefore the
area of the turning moment diagram represents the work done per revolution
4. Explain the turning moment diagram of a four stroke cycle internal combustion
engine.
In four stroke cycle internal combustion engine, there is one working stroke after the crank has
turned through two revolutions, i.e. 720° (or 4 π radians).
Since the pressure inside the engine cylinder is less than the atmospheric pressure
during the suction stroke, therefore a negative loop is formed as shown in Fig.
During the compression stroke, the work is done on the gases, therefore a higher
negative loop is obtained.
During the expansion or working stroke, the fuel burns and the gases expand, therefore
a large positive loop is obtained. In this stroke, the work is done by the gases.
During exhaust stroke, the work is done on the gases, therefore a negative loop is
formed
5. Discuss the turning moment diagram of a multicylinder engine.
A separate turning moment diagram for a compound steam engine having three
cylinders and the resultant turning moment diagram is shown in Fig. The resultant
turning moment diagram is the sum of the turning moment diagrams for the three
cylinders. It may be noted that the first cylinder is the high pressure cylinder, second
cylinder is the intermediate cylinder and the third cylinder is the low pressure cylinder.
The cranks, in case of three cylinders, are usually placed at 120° to each other.
6. Explain the terms ‘fluctuation of energy’ and ‘fluctuation of speed’ as
applied to flywheels.
The fluctuation of energy may be determined by the turning moment diagram for one complete
cycle of operation. Consider the turning moment diagram for a single cylinder double acting
steam engine as shown in Fig.
Engine has a maximum speed either at q or at s. This is due to the fact that the flywheel
absorbs energy while the crank moves from p to q and from r to s. On the other hand,
the engine has a minimum speed either at p or at r. The reason is that the flywheel gives
out some of its energy when the crank moves from a to p and q to r. The difference
between the maximum and the minimum energies is known as maximum fluctuation
of energy.
7. Define the terms ‘coefficient of fluctuation of energy’ and ‘coefficient of
fluctuation of speed’, in the case of flywheels.
8. What is the function of a flywheel? How does it differ from that of a
governor?
A flywheel is a mechanical device that uses the conservation of angular momentum to
store rotational energy; a form of kinetic energy that is proportional to the product of its
moment of inertia and the square of its rotational speed.
A flywheel is a heavy wheel attached to a rotating shaft to smooth the transfer of power
from an engine to a machine. In automobile engines, the flywheel serves to smooth out the
pulses of energy provided by combustion in the cylinders and provide energy for the
compression stroke of the pistons.
Functions of Flywheel
 Smoothing the power output of an energy source. Flywheels are used in reciprocating
engines, for example, because the active torque of the individual pistons is intermittent.
 Energy storage systems
 Delivery of energy at rates that are beyond the capabilities of an energy source. It does
this by collecting energy in a flywheel over time and then rapidly releasing it at rates
that are beyond the capabilities of the energy source.
 Control the alignment of a mechanical system, gyroscope, and reaction wheel
9. Explain the force analysis in IC Engine Mechanism
An engine is acted upon by various forces such as weight of reciprocating masses
and connecting rod, gas forces, forces due to friction and inertia forces due to
acceleration and retardation of engine elements, the last being dynamic in nature.
The analysis is made of the forces neglecting the effect of the weight and the
inertia effect of the connecting rod.
Refer Class note and learn derivation and numerical

problems from this topic
MODULE 3 & 4
1. Explain the steps involved in the design process.
1. Recognition of need. First of all, make a complete statement of the problem,

indicating theneed, aim or purpose for which the machine is to be designed.
2. Synthesis (Mechanisms). Select the possible mechanism or group of mechanisms
which will give the desired motion.
3. Analysis of forces. Find the forces acting on each member of the machine and the
energytransmitted by each member.
4. Material selection. Select the material best suited for each member of the machine.
5. Design of elements (Size and Stresses). Find the size of each member of the machine
by considering the force acting on the member and the permissible stresses for the
material used. It should be kept in mind that each member should not deflect or deform
than the permissible limit.
6. Modification. Modify the size of the member to agree with the past experience
and judgment to facilitate manufacture. The modification may also be necessary by
consideration of manufacturing to reduce overall cost.
7. Detailed drawing. Draw the detailed drawing of each component and the assembly
of the machine with complete specification for the manufacturing processes
suggested.
8. Production. The component, as per the drawing, is manufactured in the workshop.
The flow chart for the general procedure in machine design is shown in Fig.
2. Distinguish between standards and codes .
Standardization is defined as obligatory norms, to which various characteristics of
a product should conform. The characteristics include materials, dimensions and shape of
the component, method of testing and method of marking, packing and storing of the
product. The following standards are used in mechanical engineering design:
The following standards are used in mechanical engineering design:

1. Standards for materials, their chemical compositions, mechanical properties
and heat treatment.
2. Shapes and dimensions of commonly used machine elements such as bolts,
screws and nuts, rivets, belts and chains, bearings, wire ropes, keys, gears etc..
3. Standards for fits, tolerances and surface finish of components.
4. Standards for testing of products such as pressure vessels, boilers, overhead
traveling cranes.
5. Standards for engineering drawing of components.
Objective of Standardization
 To make the mass production of components easier.
 Interchangeability of components is possible due to standards.
 Repair and maintenance of machines simple because the worn out or damaged parts can
be easily replaced by standard ones.
 It aims at reduction of design, manufacturing, inventory and handling costs as well as
the efforts to achieve uniformity, efficiency and a specified quality.
3. Explain the BIS system for designation of steels based on its

composition?
Engineering materials have various compositions, types, Applications, properties.
Every material has its different mechanical properties, The Bureau of Indian Standards (
BIS ). have standardized the designation method for steel and other material. These
standards are mainly followed by Indian industries, other countries may be using ASME
standard.
The plain carbon steels varying from 0.06% carbon to 1.5% carbon are divided
into the following types depending upon the carbon content.
1. Dead mild steel — up to 0.15% carbon
2. Low carbon or mild steel — 0.15% to 0.45% carbon
3. Medium carbon steel — 0.45% to 0.8% carbon
4. High carbon steel — 0.8% to 1.5% carbon
A large number of varieties of steel are used for machine components. Steels are
designated by a group of letters or numbers indicating any one of the following three
properties:
 tensile strength
 carbon content
 composition of alloying elements.
Examples
i) Identify the Material and Composition:

a) X 10 Cr18Ni9Mo4Si2 :
Material: High alloy steel
Composition: Avg. 0.1% Carbon, 18% chromium,9% nickel, 4%
Molebdenum,2% Silicon.
b) XT 72 W 18 Cr 4 V 1 :
Material: High-speed tool steel
Composition: average carbon content 0.72 %, tungsten 18 %, chromium 4 %
and vanadium 1 %.
ii) Give the composition of
a) FeE220: Steel having a yield strength of 220 N/mm2.
b) 20C8 : Carbon steel containing 0.15 to 0.25 percent (0.2 percent on average)
carbon and 0.60 to 0.90 percent (0.80 percent on average) manganese.
iii) State the following material specifications.

a) FeE 230 –steel (Steel having a yield strength of 230 N/mm2) with a minimum
tensile strength of 230 N/mm2
b) FG 200- Grey cast iron with a minimum tensile strength of 200 N/mm2
c) 35C8 Means a carbon steel containing avg. percentage of carbon is 0.35 and
avg. percentage of manganese is 0.8.
d) X20Cr18Ni12 –Means alloy steel with an average percentage of carbon is
0.20, the average percentage of chromium is 25 , the average percentage of
nickel is 12
4. What do you mean by preferred numbers? Explain with the help of an

example.
In industrial design, preferred numbers (also called preferred values or preferred
series) are standard guidelines for choosing exact product dimensions within a given set
of constraints. Product developers must choose numerous lengths, distances, diameters,
volumes, and other characteristic quantities.
It is a series of numbers in a geometric progression (G.P) specially selected to
be used for standardization in preference to any other random numbers.
They are written as integral powers of 10. The first four are called basic series
and other are called derived series, (denoted as R5, R10, R20, R40 and R80 series)
which increase in steps of 58%, 26%, 12%, 6%, and 3% respectively. Each series has
its own series factor. The series factors are as follows:
R5 series 5√10 = 1.58

R10 series 10√10 = 1.26
R20 series 20√10 = 1.12
R40 series 40√10 = 1.06
R80 series 80√10 = 1.03
Examples: Hydraulic cylinder capacities are in R5 series

Hoisting capacities (in tones) of cranes are in R10 series
Wire diameters of helical spring are in R40series
Hydraulic cylinder diameters are in R20 series
Preferred numbers are an important tool, which minimize unnecessary variation in
sizes. They assist the designer in avoiding selection of sizes in an arbitrary manner. The
complete range is covered by minimum number of sizes which is advantageous to producer
and consumer. They are unlimited towards the lower as well as higher numbers.
5. Draw the engineering stress-strain diagram of mild steel (ductile) and explain the
salient points on it. ( Design Data handbook : Page 1)
The significance for the points on the graph are given below:
Proportional Limit: This limit is represented by point A on the graph. Up to this
limit, the stress and the strain induced in the specimen are directly proportional to each
other, i.e. the specimen obeys Hooke’s law. Beyond this point, the stress is not
proportional to the strain.
Elastic Limit: This limit is represented by point B on the graph. Upto this limit,
the material is said to be elastic. This implies that the specimen regains its original shape
and dimensions after the removal of the external load. There are no residual deformations
seen in the specimen, on removal of the load. After this point, the material is said to
become plastic.
Yield Point: Contrary to what the name suggests, this is a region rather than a
point. It is limited by the upper yield point ‘C’ and the lower yield point ‘D’. The stress –
strain curve in this part of the graph is almost horizontal, which implies that there is an
appreciable increase in strain for a negligible increase in stress. Yielding starts at ‘C’ and
ends at ‘D’. After the point ‘D’, the material, due to strain hardening again starts taking
load and the curve rises, as seen in the figure. The material now is said to be plastic and
the deformation is of nearly permanent nature.
Ultimate Stress: This is shown by the point ‘E’ on the graph. It represents the
maximum stress that a material can take before it fails. The specimen however does not
fail at this point. After this point, the curve starts dropping.
Breaking Point: This is the point at which the specimen fails. After the ultimate
stress point, necking of the specimen takes place, which causes a loss in the load carrying
capacity of the specimen and ultimately causes it to fail. This point is represented on the
curve, by point ‘F’.
6. Distinguish between ductile and brittle materials with the help of a stress- strain
diagram?
or
Draw the stress- strain behaviour of the following materials
i) Ductile ii) brittle and iii) perfectly elastic-plastic
7. What is factor of safety? What are the factors affecting factor of safety?
 Higher the factor of safety that indication of high chance of safety and low risk.
 The magnitude of the factor of safety depending on the following factors:-
 Effect of failure
 Material of components
 Type of loads
 Degree of accuracy in forces
 Reliability of machine elements
 Cost of elements
 Quality of manufacturing
 Testing of machine elements.
8. Define the term notch sensitivity. Establish the relationship between notch
sensitivity and fatigue stress concentration factor.
Or
What is notch sensitivity factor and explain its significance in the design under dynamic
loading.
In cyclic loading, the effect of the notch or the fillet is usually less than predicted
by the use of the theoretical factors as discussed before.
Notch Sensitivity is defined as the degree to which the theoretical effect of stress
concentration is actually reached. The stress gradient depends mainly on the radius of the
notch, hole or fillet and on the grain size of the material.
When the notch sensitivity factor q is used in cyclic loading, then fatigue stress
concentration factor may be obtained from the following relations
9. Explain the procedure to determine the endurance limit of a material. Also plot the
SN curve for steel and aluminium.
OR
Explain the procedure for the design of a component for finite life under varying
amplitude loading?
OR
How will you design a component made of steel subjected to variable load for a
finite life?
It has been found experimentally that when a material is subjected to repeated
stresses, it fails at stresses below the yield point stresses. Such type of failure of a
material is known as fatigue. The failure is caused by means of a progressive crack
formation which are usually fine and of microscopic size. The failure may occur even
without any prior indication
Rotating mirror beam method is used. In this method, a standard mirror
polished specimen
 A standard mirror polished specimen, as shown in Fig. is rotated in a fatigue testing

machine while the specimen is loaded in bending.
 As the specimen rotates, the bending stress at the upper fibres varies from maximum
compressive to maximum tensile while the bending stress at the lower fibres varies
from maximum tensile to maximum compressive.
 In other words, the specimen is subjected to a completely reversed stress cycle.
 A little consideration will show that if the stress is kept below a certain value as
shown by dotted line in Fig., the material will not fail whatever may be the number of
cycles. This stress, as represented by dotted line, is known as endurance or fatigue
limit .
 Endurance or Fatigue limit : It is defined as maximum value of the completely

reversed bending stress which a polished standard specimen can withstand without
failure, for infinite number of cycles (usually 107 cycles).
 Endurance strength may be used when referring the fatigue strength of the material.
It may be defined as the safe maximum stress which can be applied to the machine
part working under actual conditions.
10. What is S-N Curve ( Wohler’s Curve).What is its use?
Endurance Limit: It is defined as maximum value of the completely reversed

bending stress which a polished standard specimen can withstand without failure, for
infinite number of cycles (usually 107 cycles).It is known as endurance or fatigue limit
(ϭe).
Engineers use this method to determine the fatigue life of a material.
11. Explain the effect of stress concentration on ductile and brittle materials under
static and variable loading( cyclic loading ).
Static loading, stress concentration in ductile materials is not so serious as in
brittle materials, because in ductile materials local deformation or yielding takes place
which reduces the concentration. In brittle materials, cracks may appear at these local
concentrations of stress which will increase the stress over the rest of the section.
It is, therefore, necessary that in designing parts of brittle materials such as castings, care
should be taken. In order to avoid failure due to stress concentration, fillets at the changes
of section must be provided.
Cyclic loading, stress concentration in ductile materials is always serious
because the ductility of the material is not effective in relieving the concentration of
stress caused by cracks, flaws, surface roughness, or any sharp discontinuity in the
geometrical form of the member. If the stress at any point in a member is above the
endurance limit of the material, a crack may develop under the action of repeated load
and the crack will lead to failure of the member.
12. What is fatigue stress concentration factor?
When a machine member is subjected to cyclic or fatigue loading, the value of
fatigue stress concentration factor shall be applied instead of theoretical stress
concentration factor. Since the determination of fatigue stress concentration factor is
not an easy task, therefore from experimental tests it is defined as
13. What are the factors affecting the endurance strength?

OR
What are the endurance strength modification factors?
The endurance limit (σe) of a material as determined by the rotating beam method
is for reversed bending load. There are many machine members which are subjected to
loads other than reversed bending loads.
(a) Effect of Loading on Endurance Limit—Load Factor (A) (Design Data:

Handbook Pg 2.21 e /page 25)
The RR Moore test is conducted on a specimen that is in pure bending .Components

that are axially loaded will have all their fibers under maximum stress. The fatigue
strength should be adjusted to reflect this condition. The correction factor (A) for
load is incorporated to take care of different loads, ie; reversed bending, reversed
axial load and reversed torsional load.
A= Load correction factor for the reversed or rotating bending load =1
A= Load correction factor for the reversed axial load = 0.7 to 1.0
A = Load correction factor for the reversed torsional load (0.5 to 0.6).
(b) Effect of Size on Endurance Limit—Size Correction Factor (B)
The fatigue failure of a material is based on the probability that a larger part is more
likely to fail at lower stress due to the presence of flaw in larger stressed volume. This
is because a longer specimen will have more defects than a smaller one.
If the size of the standard specimen as shown in Fig. (a) is increased, then the
endurance limit of the material will decrease.
Where, B=1 , for d < 8mm

B=0.85, for 8 < d < 50 mm
B=0.7 , for d > 50 mm
(c) Effect of Surface Finish on Endurance Limit—Surface Correction Factor( C)
The rotating beam specimen has a highly polished surface finish with final polishing
in axial direction to smooth are circumferential scratches. Most machine elements do not
usually have such high quality finish. The surface modification factor depends on process
used to generate the surface and on the ultimate strength .
When the surface finish factor is known, then the endurance limit for the material of
the machine member may be obtained by multiplying the endurance limit and the surface
finish factor.
The endurance limit for mirror polished material is maximum and it goes on reducing
due to surface condition.
Where C from Design Data handbook ,Table 2.2 Page 32
(d) Reliability factor
The laboratory values of endurance limit are usually mean values. There is
considerable dispersion of the data when a number of tests are conducted even using the
same material and same conditions. The standard deviation of endurance limit tests is
8% of the mean value.
The reliability factor depends on the survival rate of the component at a particular
stress. The greater the likelihood that a part will survive, the more is the reliability and
lower is the reliability factor. The reliability factor is one for 50% reliability. This means
that 50% of the components will survive in the given set of conditions.
14. Explain Soderberg, Goodman and Gerber’s criteria for design under fatigue
loading.
 Mean stress as well as stress amplitude exist when a component is subjected to
fluctuating stresses.
 It has been observed that the mean stress component has an effect on fatigue
failure when it is present in combination with an alternating component.
 The fatigue diagram for this general case is shown in Fig. below. In this diagram,
the mean stress is plotted on the abscissa and stress amplitude on ordinate.
 The magnitudes of mean stress and stress amplitude depend upon the magnitudes
of maximum and minimum force acting on the component.
 When stress amplitude is zero, the load is purely static and the criterion of failure
is Sut or Syt. These limits are plotted on the abscissa.
 When the mean stress is zero, the stress is completely reversing and the criterion
of failure is the endurance limit Se that is plotted on the ordinate.
 When the component is subjected to both components of stress, the actual failure
occurs at different scattered points shown in the figure.
 There exists a border, which divides safe region from unsafe region for various
combinations of mean stress and stress amplitude.
 Different criterion are proposed to construct the borderline dividing safe zone and
failure zone. They include Gerber line, Soderberg line and Goodman line.
 Gerber Line: A parabolic curve joining σen on the ordinate to σu on the abscissa is
called the Gerber line.
 Soderberg Line: A straight line joining σen on the ordinate to σu on the abscissa is
called the Soderberg line.
 Goodman Line: A straight line joining σen on the ordinate to σyp on the abscissa is
called the Goodman line.
15. Define Stress Concentration .Give any three methods to reduce stress concentration.
Whenever the machine component changes the shape of its cross-section the
stress distribution pattern no longer holds good and the neighborhood of the discontinuity
is different. The stresses induced in the neighborhood are much higher than the stress
induced in the other part of the component. This abrupt change in cross-section or the
discontinuity form is called stress concentration.
 It occurs for all kind of stresses in the presence of fillets, notches, holes, key-
ways, splines, surface roughness are scratches etc
 It is for all kinds of stresses caused due to keyways, grooves, notches, roughness,
or scratches.
Causes of Stress Concentration
 Variation in Properties of Materials

 Load Application
 Abrupt Changes in Section
 Discontinuities in the Component
 Machining Scratches
Methods to Reduce Stress Concentration
1. Additional Notches and Holes in Tension Member
 A flat plate with a V-notch subjected to tensile force is shown in Fig. (a).
 It is observed that a single notch results in a high degree of stress concentration.
 The severity of stress concentration is reduced by three methods: (a) Use of multiple notches,
(b) Drilling additional holes; and (c) Removal of undesired material.
2. Fillet Radius, Undercutting and Notch for Member in Bending:

 A bar of circular cross-section with a shoulder and subjected to bending moment
is shown in Fig. (a).
 Ball bearings, gears or pulleys are seated against this shoulder.
 The shoulder creates a change in the cross-section of the shaft, which results in
stress concentration.
 There are three methods to reduce stress concentration at the base of this shoulder.
17. Compare the endurance properties of steel and aluminium by using S-N curve
 Ferrous metals and alloys : SN curve becomes horizontal after certain number of cycles
Indicating that an endurance limit is reached below which failure will not occur.
Eg : Low strength carbon and alloy steels, iron ,titanium alloys etc
 Nonferrous metals and alloys : Fatigue strength continues to decrease with increasing
cycles and do not have significant endurance limit. Fatigue occurs irrespective of stress
amplitude.
Eg: Aluminium , Magnesium ,copper , nickel etc
Module 5
1. What is Surging in Springs?.Explain how it occurs. What is its effect
2. What is nipping in leaf springs? Explain its purpose
3. What are the requirements of spring material?
4. Why the leaf springs are laminated?
5. Why do we consider Wahl’s factor for the design of helical compression springs?
OR
What are the stresses acting in wire of helical spring .Sketch its distribution
6. Derive the expression for the stress in graduated semi-elliptical leaf spring.
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Terms used in Compression Springs
The following terms used in connection with compression springs are important from the subject
point of view.
1. Solid length. When the compression spring is compressed until the coils come in contact with
each other, then the spring is said to be solid. The solid length of a spring is the product of total
number of coils and the diameter of the wire.
2. Free length. The free length of a compression spring, as shown in Fig. is the length of the spring
in the free or unloaded condition. It is equal to the solid length plus the maximum deflection or
compression of the spring and the clearance between the adjacent coils (when fully
compressed).
3. Spring index. The spring index is defined as the ratio of the mean diameter of the coil to the
diameter of the wire.
4. Spring rate. The spring rate (or stiffness or spring constant) is defined as the load required per
unit deflection of the spring.
5. Pitch. The pitch of the coil is defined as the axial distance between adjacent coils in
uncompressed state.
In choosing the pitch of the coils, the following points should be noted :
(a) The pitch of the coils should be such that if the spring is accidently or carelessly
compressed,
the stress does not increase the yield point stress in torsion.
(b) The spring should not close up before the maximum service load is reached.
End Connections for Compression Helical Springs
 In all springs, the end coils produce an eccentric application of the load, increasing the stress on
one side of the spring. Under certain conditions, especially where the number of coils is small,
this effect must be taken into account.
 The nearest approach to an axial load is secured by squared and ground ends, where the end
turns are squared and then ground perpendicular to the helix axis.
 It may be noted that part of the coil which is in contact with the seat does not contribute to
spring action and hence are termed as inactive coils. The turns which impart spring action are
known as active turns.
Buckling of Compression Springs
It has been found experimentally that when the free length of the spring (LF) is more than four
times the mean or pitch diameter (D), then the spring behaves like a column and may fail by buckling at
a comparatively low load as shown in Fig.
1. What is Surging in Springs?.Explain how it occurs. What is its effect

Surge in Springs
 When one end of a helical spring is resting on a rigid support and the other end is loaded
suddenly, then all the coils of the spring will not suddenly deflect equally, because some time is
required for the propagation of stress along the spring wire.
 A little consideration will show that in the beginning, the end coils of the spring in contact with
the applied load takes up whole of the deflection and then it transmits a large part of its
deflection to the adjacent coils.
 In this way, a wave of compression propagates through the coils to the supported end from
where it is reflected back to the deflected end. This wave of compression travels along the
spring indefinitely.
 If the applied load is of fluctuating type as in the case of valve spring in internal combustion
engines and if the time interval between the load applications is equal to the time required for
the wave to travel from one end to the other end, then resonance will occur. This results in very
large deflections of the coils and correspondingly very high stresses. Under these conditions, it is
just possible that the spring may fail. This phenomenon is called surge.
The surge in springs may be eliminated by using the following methods:

 By using friction dampers on the centre coils so that the wave propagation dies out.
 By using springs of high natural frequency.
 By using springs having pitch of the coils near the ends different than at the centre to
have different natural frequencies.
Helical Springs Subjected to Fatigue Loading
 The helical springs subjected to fatigue loading are designed by using the *Soderberg
line
 method. The spring materials are usually tested for torsional endurance strength under
a repeated
 stress that varies from zero to a maximum. Since the springs are ordinarily loaded in one
direction
 only (the load in springs is never reversed in nature), therefore a modified Soderberg
diagram is used for springs, as shown in Fig.
2. What is nipping in leaf springs? Explain its purpose

The stress in the full length leaves is 50% greater than the stress in the graduated leaves. In
order to utilise the material to the best advantage, all the leaves should be equally stressed.
This condition may be obtained in the following two ways :
1. By making the full length leaves of smaller thickness than the graduated leaves. In this way,
the full length leaves will induce smaller bending stress due to small distance from the neutral axis to
the edge of the leaf.
2. By giving a greater radius of curvature to the full length leaves than graduated leaves, as
shown in Fig., before the leaves are assembled to form a spring. By doing so, a gap or clearance will be
left between the leaves. This initial gap, as shown by C in Fig., is called nip. When the central bolt,
holding the various leaves together, is tightened, the full length leaf will bend back as shown dotted in
Fig. and have an initial stress in a direction opposite to that of the normal load.
The graduated leaves will have an initial stress in the same direction as that of the normal load.
When the load is gradually applied to the spring, the full length leaf is first relieved of this initial stress
and then stressed in opposite direction. Consequently, the full length leaf will be stressed less than the
graduated leaf. The initial gap between the leaves may be adjusted so that under maximum load
condition the stress in all the leaves is equal, or if desired, the full length leaves may have the lower
stress. This is desirable in automobile springs in which full length leaves are designed for lower stress
because the full length leaves carry additional loads caused by the swaying of the car, twisting and in
some cases due to driving the car through the rear springs.
3. What are the requirements of spring material

The selection of material for the spring wire depends upon the following factors:
 The load acting on the spring
 The range of stress through which the spring operates
 The limitations on mass and volume of spring
 The expected fatigue life
 The environmental conditions in which the spring will operate such as temperature and
corrosive atmosphere
 The severity of deformation encountered while making the spring.
There are four basic varieties of steel wire which are used in springs in the majority of
applications
 patented and cold-drawn steel wires (unalloyed);
 oil-hardened and tempered spring steel wires and valve spring wires;
 oil-hardened and tempered steel wires (alloyed); and
 stainless steel spring wires.
The most extensively used spring material is high-carbon hard-drawn spring steel. It is often
called ‘patented and cold-drawn’ steel wire. There are two important terms related to patented and
cold-drawn steel wires, namely, ‘patenting’ and ‘cold drawing’. Patenting is defined as heating the steel
to above the critical range followed by rapid cooling to transform at an elevated temperature from 455°
to 465°C. This operation produces a tough uniform structure that is suitable for severe cold drawing.
After this operation, the spring wire is produced from hot rolled rods by cold drawing through carbide
dies to obtain the required diameter.
The patented and cold drawn steel wires are made of high carbon steel and contain 0.85–0.95%
carbon. It is considered an aristocrat among springs because it has high tensile strength, high elastic
limit and the ability to withstand high stresses under repeated loadings. The patented and cold-drawn
steel wires are the least expensive of all spring materials. The music spring wire is the highest quality of
hard drawn steel spring. The name ‘music wire’ is derived from the popular ‘piano’ wire that was
originally used in musical instruments.
4. Why the leaf springs are laminated?
Laminated or Leaf Springs
Due to low cost and simple connection to axle, the leaf springs are very popular for rear
suspension. The most commonly used leaf spring is the semi-elliptic type, consisting of one main leaf,
which usually has its ends formed into eyes for connection with the spring brackets, and a number of
shorter leaves, the length of which gradually and uniformly decreases from the main leaf. The various
leaves are held together by a centre bolt. The main details of a semi-elliptic spring are presented in Fig.
To obtain a constant stress throughout the spring the leaves are graduated in length. Rebound
clips transmit the load to some of the lower leaves during the return motion of the spring, and thus
eliminate the need for using large number of leaves above the main plate. Rubber bushes, fitted in each
eye, allow for movement of the spring, and act as noise insulators.
A swinging shackle accommodates the alteration in spring length.
The force required for unit deflection of a spring is called the stiffness or rate of the spring.
The stiffness of a spring depends on the
(i) length of spring (shorter spring, higher stiffness),

(ii) width of leaf (wider spring, higher stiffness)
5. Why do we consider Wahl’s factor for the design of helical compression

springs? Or
What are the stresses acting in wire of helical spring .Sketch its
distribution
6. What is weld reinforcement? Why is it done?
Weld metal in excess of the quantity required to fill a weld groove.
Excessive reinforcement is one type of defect in Weld, so it adjusted as per permissible
height of reinforcement as per ASME. After welding excessive reinforcement removed by
grinding operation.
Since the weld is weaker than the plate due to slag and blow holes, therefore the weld is
given a reinforcement which may be taken as 10% of the plate thickness.
7. Compare welded joints with riveted joints?

Advantages and Disadvantages of Welded Joints over Riveted Joints
Advantages
 The welded structures are usually lighter than riveted structures. This is due to the
reason, that in welding, gussets or other connecting components are not used.
 The welded joints provide maximum efficiency (may be 100%) which is not possible in
case of riveted joints.
 Alterations and additions can be easily made in the existing structures.
 As the welded structure is smooth in appearance, therefore it looks pleasing.
 In welded connections, the tension members are not weakened as in the case of riveted
joints.
 A welded joint has a great strength. Often a welded joint has the strength of the parent
metal itself.
 The process of welding takes less time than the riveting.
Disadvantages
 Since there is an uneven heating and cooling during fabrication, therefore the members
may get distorted or additional stresses may develop.
 It requires a highly skilled labour and supervision.
 Since no provision is kept for expansion and contraction in the frame therefore the
members possibility of cracks developing in it.
 The inspection of welding work is more difficult than riveting work.
8. Show by neat sketches the various modes of failure of riveted joint?

OR
What are the failure modes of a riveted joint? OR
Explain the failures modes of riveted joints and how will you determine
the efficiency of a rivet joint? OR
What are the different types of keys? (any four); and explain its failure
modes.
Failures of a Riveted Joint:
A riveted joint may fail in the following ways :
1. Tearing of the plate at an edge. A joint may fail due to tearing of the plate at an edge as
shown in Fig. This can be avoided by keeping the margin, m = 1.5d, where d is the diameter of
the rivet hole.
2. Tearing of the plate across a row of rivets. Due to the tensile stresses in the main plates, the
main plate or cover plates may tear off across a row of rivets as shown in Fig. In such cases, we
consider only one pitch length of the plate, since every rivet is responsible for that much length
of the plate only.
The resistance offered by the plate against tearing is known as tearing resistance or
tearing strength or tearing value of the plate.
Let p = Pitch of the rivets,
d = Diameter of the rivet hole,
t = Thickness of the plate, and
σt = Permissible tensile stress for the plate material.
We know that tearing area per pitch length,
At = (p – d ) t
∴ Tearing resistance or pull required to tear off the plate per pitch length,
Pt = At.σt = (p – d)t.σt
When the tearing resistance (Pt) is greater than the applied load (P) per pitch length,
then this type of failure will not occur.
3. Shearing of the rivets. The plates which are connected by the rivets exert tensile stress on
the rivets, and if the rivets are unable to resist the stress, they are sheared off as shown in Fig.
It may be noted that the rivets are in *single shear in a lap joint and in a single cover butt joint,
as shown in Fig.
But the rivets are in double shear in a double cover butt joint as shown in Fig.9.16. The
resistance offered by a rivet to be sheared off is known as shearing resistance or shearing
strength or shearing value of the rivet.
Let d = Diameter of the rivet hole, τ = Safe permissible shear stress for the rivet material, and
n = Number of rivets per pitch length.
4. Crushing of the plate or rivets. Sometimes, the rivets do not actually shear off under the
tensile stress, but are crushed as shown in Fig. 9.17. Due to this, the rivet hole becomes of an
oval shape and hence the joint becomes loose. The failure of rivets in such a manner is also
known as bearing failure. The area which resists this action is the projected area of the hole or
rivet on diametral plane.
The resistance offered by a rivet to be crushed is known as crushing resistance or crushing

strength or bearing value of the rivet.
Let d = Diameter of the rivet hole,
t = Thickness of the plate,
σc = Safe permissible crushing stress for the rivet or plate material, and
n = Number of rivets per pitch length under crushing.
We know that crushing area per rivet (i.e. projected area per rivet)
Ac = d.t
∴ Total crushing area = n.d.t
and crushing resistance or pull required to crush the rivet per pitch length
Pc = n.d.t.σc
When the crushing resistance (Pc) is greater than the applied load (P) per pitch length, then this
type of failure will occur.
MODULE 1 TO 5
IMPORTANT SHORT QUESTIONS AND THEORY QUESTIONS
MODULE 1:
1. Explain D’ Alembert’s principle.
2. Determine analytically the forces such as piston effort, force in the connecting rod and side
thrust on the cylinder walls of a reciprocating engine.
3. Draw the turning moment diagram of IC engine.
4. Derive an expression for the coefficient of fluctuation of energy.
5. Derive an expression relating the stress in a flywheel and its linear speed.
MODULE 2
1. Explain the energy method and Newton’s method to determine the natural frequencies of
a single degree of freedom system.
2. Derive an expression for the logarithmic decrement.
3. Find the forced response of a damped single degree of freedom vibrating system subjected
to a harmonic excitation.
4. Distinguish between motion transmissibility and force transmissibility.
5. What is whirling? Derive an expression for the critical speed of a shaft.
MODULE 3:
1. Find the natural frequencies and mode shapes of a two degree freedom vibrating system.
2. What do you mean by eigenvalues and eigenvectors of a multi degree freedom vibrating
system?
3. What are the steps in the design process?
4. Define stress concentration factor. How can we minimize it?
MODULE 4:
1. Explain Goodman’s criterion.
2. Explain Soderberg’s criterion.
3. Define endurance limit and factor of safety.
4. Derive an expression for the impact stress due to a freely falling body.
5. Describe the modes of failure of a riveted joint.
6. What are the different efficiencies of a riveted joint?
7. Classify the riveted joints.
MODULE 5
1. What are the different types of welded joint?
2. Describe AWS welding symbols with neat sketches.
3. Determine the weld size of a joint subjected to axial, bending and twisting loads.
4. Derive an expression for the shear stress in the spring wire.
5. Derive an expression for the deflection of a helical compression spring.
6. Why concentric springs are required in certain applications?

Important Short Questions DYNAMICS AND DESIGN OF MACHINERY

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Important Short Questions DYNAMICS AND DESIGN OF MACHINERY

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MET304 : DYNAMICS AND DESIGN OF MACHINERY

1. Define D’Alembert’s principle.

3. Draw the turning moment diagram of a single cylinder double acting

Refer Class note and learn derivation and numerical

1. Explain the steps involved in the design process.

1. Recognition of need. First of all, make a complete statement of the problem,

2. Distinguish between standards and codes .

The following standards are used in mechanical engineering design:

3. Explain the BIS system for designation of steels based on its

i) Identify the Material and Composition:

iii) State the following material specifications.

4. What do you mean by preferred numbers? Explain with the help of an

R5 series 5√10 = 1.58

Examples: Hydraulic cylinder capacities are in R5 series

 A standard mirror polished specimen, as shown in Fig. is rotated in a fatigue testing

 Endurance or Fatigue limit : It is defined as maximum value of the completely

10. What is S-N Curve ( Wohler’s Curve).What is its use?

Endurance Limit: It is defined as maximum value of the completely reversed

13. What are the factors affecting the endurance strength?

(a) Effect of Loading on Endurance Limit—Load Factor (A) (Design Data:

The RR Moore test is conducted on a specimen that is in pure bending .Components

Where, B=1 , for d < 8mm

(c) Effect of Surface Finish on Endurance Limit—Surface Correction Factor( C)

(d) Reliability factor

 Variation in Properties of Materials

Methods to Reduce Stress Concentration

1. Additional Notches and Holes in Tension Member

2. Fillet Radius, Undercutting and Notch for Member in Bending:

End Connections for Compression Helical Springs

1. What is Surging in Springs?.Explain how it occurs. What is its effect

The surge in springs may be eliminated by using the following methods:

Helical Springs Subjected to Fatigue Loading

2. What is nipping in leaf springs? Explain its purpose

3. What are the requirements of spring material

4. Why the leaf springs are laminated?

Laminated or Leaf Springs

(i) length of spring (shorter spring, higher stiffness),

5. Why do we consider Wahl’s factor for the design of helical compression

7. Compare welded joints with riveted joints?

8. Show by neat sketches the various modes of failure of riveted joint?

The resistance offered by a rivet to be crushed is known as crushing resistance or crushing

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