1. What do you mean by factor of safety?

Factor of safety is

• The ratio of a structure's absolute strength (structural capability) to actual applied load;
• a measure of the reliability of a particular design
• a calculated value, and is sometimes referred to, for the sake of clarity, as a realized
factor of safety.
• Factor of safety (FoS) is an engineering term used to describe a margin of safety against
failure.
• It is usually expressed as a ratio of the maximum stress that an object can sustain
before failing, divided by the stress that it is actually experiencing.
• FoS is also known as Safety Factor (SF) and is used as a guideline in many engineering
applications.

2, What is meant by eccentric loading and eccentricity?

Eccentric loading is a type of applied load that acts on a structure in an off-center
manner, resulting in an eccentric moment. This type of loading is frequently
encountered during the operation of machinery and when performing tests to
determine the strength and stability of structures. Eccentricity in engineering relates to
the degree of difference between two points that are not at exactly the same location.
In other words, it is the amount by which an object deviates from being perfectly
symmetrical or centralized. Eccentricity can refer to off-axis loads, where weight makes
objects fall off-center, or when parts do not fit correctly together due to their shapes,
leading to additional stress concentrations on certain areas.
3, Illustrate how the stress concentration in a component can be reduced.
1. Improve design: Use an optimized shape that reduces the stress concentration factor and
removes sharp edges and dramatic changes in geometry.
2. Modify material: Use a combination of higher strength materials and softer materials
to reduce the stress levels. This technique is commonly used in high-performance components.
3. Add support structures: Adding additional structures such as webs, ribs, gussets, etc.,
can reinforce the weaker areas of a component and spread the load over a larger area which in
turn will reduce the stress concentration.
4. Use composite materials: Using composite materials such as carbon fiber reinforced
plastic (CFRP) can help reduce stress concentration by providing uniform loading characteristics
along with better strength-to-weight ratios when compared to metals, allowing for more
reliable components with reduced stresses
4. Explain design process with neat diagram.
5. Explain following failure theories in details.
a. Maximum strain energy theory
is a theoretical framework that is used to predict the failure of brittle and ductile materials
under tension. It states that the material fails when the strain energy stored in the material
reaches its maximum value. This value is dependent on the material's properties such as its
elastic modulus, yield strength, and fracture toughness. The theory is based on the concept
of energy stored in a material due to the applied stress. When a material is subjected to a
tensile load, the atoms and molecules within the material are pulled apart, leading to the
development of internal strains. These strains store energy in the material, which is referred
to as strain energy
b. Maximum principal stress theory
Maximum Principal Stress theory, also known as the Mohr's Circle theory, is a method used
to determine the state of stress at a point in a material. It assumes that the material
behaves in a linear elastic manner, and that the stresses acting on the material are in the
form of principal stresses. These are the maximum and minimum normal stresses acting on
the material at that point. The theory can be used to calculate these stresses and the
direction in which they act, using the stresses and strains measured in different planes. The
Mohr's circle is a graphical representation of the maximum principal stress theory that is
used to analyze and understand the behavior of materials under stress.
6. Define the following properties of a material
a.Ductility is the ability of a material to be drawn into thin wires. It is measured as the
percentage elongation in a tensile specimen. This property also allows materials to undergo
bending, folding and other deformations without breaking or fracturing.
b.Creep is a time-dependent deformation that materials may experience when loaded beyond
their yield strength. An increase in temperature can lead to an increase in the material’s creep
rate, which can become permanent deformation if left unchecked. Creep usually occurs at
elevated temperatures, when stress levels are close to yield strength, and with time dependent
loading conditions such as static loads or heat radiation from fires.
7. What is meant by endurance limit?
Endurance limit is a concept used in mechanical engineering and materials science to describe the
maximum stress level (often given in terms of force per unit area) that a material can withstand for a
given number of cycles without failure. It is also known as fatigue limit or endurance strength

8. What types of stresses are induced in shafts?

Stresses induced in shafts include torsional, bending, axial, bearing and fatigue.

9. What is a key? State its function.

A key is a device used to connect two rotating machines together, usually in the form of a short thin rod.
It is inserted between two parallel components, such as a shaft and hub, and applies force to partially
hollow mating surfaces on each component in order to prevent movement relative to each other. The
key functions by providing shear strength sufficient enough to join the parts with a strong mechanical
bond.

10. Sketch the various types of welded joints.

11. Define pitch and lead with respect to threads.
Pitch is the distance between threads on a bolt or screw and is typically measured along the length of
the shaft in millimeters or inches. Lead refers to the linear distance a screw thread advances axially with
one revolution, and is also measured in millimeters or inches

12. Classify springs according to their shapes.

1. Barrel: These springs are cylindrical in shape and have a constant diameter throughout their length.

2. Conical: These springs are shaped like a cone and taper from one end to the other.

3. Hourglass: Also known as 'Garter' springs, these coils have hourglass-shaped cross sections that form
loops when fully extended.

4. Tapered: These springs have conical shapes and are used to apply pressure as they are compressed or
stretched out.

5. Spiral: These coiled springs take on a spiral shape when extended and can store large amounts of
energy due to their flexible design.

13. What is nipping in a leaf spring?

Nipping is the process of reinforcing the ends of leaf springs to prevent them from cracking, spreading or
popping out. This reinforcement process involves either compressing and welding the ends into a short
distance, or crimping them by hammering down circular notches. Nipping ensures that the leaf spring's
load-bearing capacity is not compromised in any way

14. What are the commonly used material for sliding contact bearings?
Sliding contact bearings are used in a variety of applications and as a result, there are a number
of different materials that can be used. Some of the most common materials used in sliding
contact bearings include:
1. Steel: Steel is a common material used for both the bearing raceway and the rolling
elements. Steel is strong, durable and can handle high loads.
2. Bronze: Bronze is a popular material used in bearings due to its good corrosion resistance
and its ability to handle high loads and high speeds.
3. Brass: Brass is often used in bearings due to its high resistance to wear and corrosion. It is
also relatively soft and able to conform to slight misalignments in the shaft.
4. Plastic: Plastic bearings are often used in applications where there is a need for low friction
and where the loads are relatively low. Some common plastics used in bearings include Delrin,
Nylon, and PTFE.
5. Ceramic: Ceramic bearings are becoming increasingly popular due to their high hardness, low
coefficient of friction, and excellent wear resistance. They are often used in high speed and high
temperature applications. It's worth noting that the choice of material for a sliding contact
bearing will depend on the specific application and the conditions under which it will be used.
15. Define coefficient of fluctuation of speed.
The coefficient of fluctuation of speed is a measure of the variance or variability in the speed
measurements. It is calculated by dividing the standard deviation by the mean value. The formula for
calculating the coefficient of fluctuation of speed is as follows:

Coefficient of fluctuation= (Standard Deviation / Mean) × 100

16. Drive Soderberg’s equation and state its application to different types of loadings

Soderberg's equation can be applied to different types of loadings, including:

1. Tensile loading: In this case, the mean stress correction factor (m) is usually set to zero, as
tensile loading does not induce mean stress.

2. Compressive loading: In this case, the mean stress correction factor (m) is usually set to 0.5,
as compressive loading induces mean stress.
3. Biaxial loading: In this case, the mean stress correction factor (m) is a function of the ratio of
the maximum compressive stress to the minimum tensile stress.

4. Torsion loading: In this case, the mean stress correction factor (m) is a function of the torque
amplitude and the maximum shear stress.
application
Soderberg's equation is widely used in engineering design and analysis, especially in the
automotive, aerospace, and power generation industries. It is a valuable tool for predicting the
fatigue life of components under cyclic loading and for determining the appropriate design
margins to ensure reliable operation.
17. Design a shaft to transmit power from an electric motor to a lathe head stock through a pulley by
means of a belt drive. The pulley weighs 200W and is locked at 300 mm from the center of the
bearing. Diameter of the pulley is 200mm. Maximum power transmitted 1.5 HP.at 120 rpm. angle of
lap of belt 180 . Coefficient of friction between belt and pulley 0.3. Shock factor in bending 1.5 shock
factor in twisting 2.0. Allowable shear stress in the shaft 35 N/mm2 .

1 MPa = 1 N/mm2 1.5hp =1.118KW 200W=200N

18.
19.The load on a bolt consists of an axial pull of 10 KN together with a transverse shear force of 5 KN.
Find the diameter of the bolt according to,

a. Maximum principal stress theory;

b. Maximum shear stress theory;

c. Maximum distortion energy theory.

20.
 QUE

21.A mild steel shaft transmits 20 KW at 200 rpm. It carries a central load of 900 N and is simply
supported between the bearings 2.5m apart. Determine the size of the shaft, if the allowable shear
stress is 42 MPa and the maximum tensile or compressive stress is not to exceed 56 MPA. What size of
the shaft will be required, if it is subjected to gradually applied loads?
22.THE SAME AS QUESTION#18
23. Describe the difference between a screw and a bolt

The major difference between a screw and a bolt is that a screw is used to join materials together by
using its own thread, whereas a bolt requires the use of a nut in order to join two pieces of material
together. Additionally, screws are typically placed into pre-drilled holes while bolts require the use of
additional tools (a ratchet or wrench) and having to be secured with nuts. Screws are also typically
smaller than bolts, and they may vary in size depending on the application.

24. Define the term proof strength.

Proof strength is the maximum stress or load that a material can withstand before it begins to yield or
permanently deform. It is an important factor in determining the suitability of a material for a particular
application and helps engineers to determine the safety margins required to ensure that the material
will perform as expected under normal operating conditions. The proof strength of a material is often
measured through tensile testing and is typically expressed in units of stress such as mega-Pascals (MPa)
or pounds per square inch (psi).

25. Define the term clamping load

Clamping load is the force or pressure that a device, such as a clamp, applies to an object to hold it in
place. This force may be static, meaning that it is held in place without further effort on the part of the
user, or dynamic, requiring continual application of the force until released. Clamping loads are used in
many applications including assembly and manufacturing, construction and aviation.

26.Specify suitable machine screws to be installed in a pattern of four, equally spaced around a flange,
if the clamping force between the flange and the mating structure is to be 6000 lb. Then recommend a
suitable tightening torque for each screw.
27.What would be the tensile force in a machine screw having an 8–32 thread if it is made from SAE
Grade 5 steel and is stressed to its proof strength?

Given data:

Thread of machine screw : 8-32

SAE Grade 5 screw

From the machiney hand book for the above stated two parameters, tensile strenght is 517.65 ksi

Also from the same table, tensile stress area is given by 0.0140 in2

We know that tensile force is given be

Substituting the known values in the above equation we have

28.A single-threaded 25-mm power screw is 25 mm in diameter with a pitch of 5 mm. A

vertical load on the screw reaches a maximum of 5kN. The coefficients of friction are 0.06 for
the collar and 0.09 for the threads. The frictional diameter of the collar is 45 mm. Find the
overall efficiency and the torque to “raise” and “lower” the load.
Given-

Major Diameter(dmajor)= 25mm

Pitch(P) =5mm= 0.005m

Axial load on screw(F)= 5 KN=5×10^3N

Coefficient of friction for thread( )=0.09

Coefficient of friction for collar( c) =0.06

Diameter of collar(dc) =45mm=0.045m

Mean diameter(dm) =dmajor -P/2

= 25- (5/2)
=22.5mm

=0.0225m

Torque required to raise the load is 15.75 Nm

b) Now we find the torque required to lower the Load-

Torque required to lower the load is 7.81 Nm

c) Now We have to find overall efficiency-

The overall efficiency is 0.252

The torque required to raise the load is 15.75 N-m

The torque required to lower the load is 7.81 N-m

The overall efficiency is 0.252

29.
30.
31.Two shafts are connected by means of a coupling to transmit 5 HP. at 1440 rpm. The flanges of
the coupling are fastened by mean of 3 bolts, at a radius of 30mm. permissible shear stress in the
bolts = 30 N/mm2 . Design the bolts. (WORKISHEETCHANGE 4 BOLTS-3 BOLTS)
 32. Determine the length of welds required to transmit a load 54.5KN between 12.7mm. thick
plates, when the plates are to be joined by

1) Two parallel fillet welds.

2) Two transverse fillet welds.

33. Design a helical spring for an engine valve length of the spring when the valve in open in
45mm. and the length when closed in 55mm. spring load on the valve when open is 450N and
when closed in 300N. Minimum internal diameter of the spring is 30mm. Take permissible shear
stress = 400 N/mm2 , and G = 0.8x 105 N/mm2 .

34.A steel Belleville spring is compressed flat by exerting a load of 1000N.for the maximum
compression, the induced stress is 1200 N/mm2 . Calculate the thickness and outside diameter of
the spring if the ratio of height to thickness is 1.6. The ratio of outside diameter to inside diameter
is 5.

35.
36. A threaded fastener is made from nylon 6/6 with an M10 * 1.5 thread. Compute the
maximum tensile force that can be permitted in the fastener if it is to be stressed to 75% of
the tensile strength of the nylon 66 dry.
37
38. design a bolted joint to join the two members shown in the appropriate figure. Specify the
number of bolts, the pattern, the bolt grade, and the bolt size.
39. For a bolted assembly with eight bolts, the stiffness of each bolt is kb = 1.0 MN/mm and the
stiffness of the members is km = 2.6 MN/mm per bolt. The bolts are preloaded to 75 percent of
proof strength. Assume the external load is equally distributed to all the bolts. The bolts are M6
× 1 class 5.8 with rolled threads. A fluctuating external load is applied to the entire joint with
Pmax = 60 kN and Pmin = 20 kN.

(a) Determine the yielding factor of safety.

(b) Determine the overload factor of safety.

(c) Determine the factor of safety based on joint separation.

(d) Determine the fatigue factor of safety using the Goodman criterion
 40. A 50 mm diameter solid shaft is welded to a flat plate as shown in Fig. If the size of the weld
is 15 mm, find the maximum normal and shear stress in the we
41. A spring has an overall length of 2.75 in when it is not loaded and a length of 1.85 in when
carrying a load of 12.0 lb. Compute its spring rate.

42. A spring is loaded initially with a load of 4.65 lb and has a length of 1.25 in. The spring rate
is given to be 18.8 lb/in. What is the free length of the spring?

43. A spring has a spring rate of 76.7 lb/in. At a load of 32.2 lb, it has a length of 0.830 in. Its
solid length is 0.626 in. Compute the force required to compress the spring to solid height. Also
compute the free length of the spring.

44. A spring has an overall length of 63.5 mm when it is not loaded and a length of 37.1 mm
when carrying a load of 99.2 N. Compute its spring rate.
45. A spring is loaded initially with a load of 54.05 N, and it has a length of 39.47 mm. The
spring rate is given to be 1.47 N/mm. What is the free length of the spring?