Term Work Questions

Machine Design 1 SEM-VI

The following design exercises also include computer aided drawing of designed
components on A3 size sheets.

1. Design and draw a cotter joint to support a load varying from 30 kN in compression to 30
kN in tension. The material used is carbon steel for which the following allowable stresses
may be used. The load is applied statically. Tensile stress = compressive stress = 50 MPa ;
shear stress = 35 MPa and crushing stress = 90 MPa.
2. Design a knuckle joint to transmit 150 kN. The design stresses may be taken as
75 MPa in tension, 60 MPa in shear and 150 MPa in compression.
3. A rigid coupling is used to transmit 20 kW power at 720 rpm. There are four bolts and the
pitch circle diameter of the bolts is 125 mm. The bolts are made of steel 45C8 (Syt = 380
N/mm2) and the factor of safety is 3. Determine the diameter of the bolts. Assume that the
bolts are finger tight in reamed and ground holes.
4. A semi-elliptic leaf spring used for automobile suspension consists of three extra full-
length leaves and 15 graduated-length leaves, including the master leaf. The centre-to-
centre distance between two eyes of the spring is 1 m. The maximum force that can act on
the spring is 75 kN. For each leaf, the ratio of width to thickness is 9:1. The modulus of
elasticity of the leaf material is 207 000 N/mm2. The leaves are pre-stressed in such a way
that when the force is maximum, the stresses induced in all leaves are same and equal to
450 N/mm2. Determine (i) the width and thickness of the leaves (ii) the initial nip; and (iii)
the initial pre-load required to close the gap C between extra full-length leaves and
graduated-length leaves.
5. Design a screw jack for supporting the machine parts during their repair and maintenance
on the shop fl oor. It should be a general-purpose jack with a load carrying capacity of 100
kN and a maximum lifting height of 0.5 m. The jack is to be manually operated.