Ry OF MACHINE ELEMENTS nx DESIGN DME 2 Unit 1: Introduction to Machine De: n Unit at a glance: The subject machine design is the creation of new and better machines and improving the existing one. A new and better machine is one which is more economical Inne overall cost of production and operation. Following are the general considerations in designing a machine component 1, Type of load and stresses caused by the load 2. Motion of the parts or kinematics of the machine 3. Selection of materials 4. Form and size of the parts 5. Frictional resistance and lubrication 6. Convenient and economical features 7. Use of standard parts 8 Safety of operation 9. Workshop facilities 10. Number of articles or units to be manufactured IL. Cost of construction 12. Assembling. Koad: is defined as any external force acting upon a machine part. The following four types of load are considered: a) Dead or steady load b) Live or variable load - ©) Suddenly applied or shock load 4) Impact load To balance the external forces, internal forces are set up at various sections of This internal force per unit area at any section of the body is known ae strove Stresses can be tensile, at the surface of contact f the body. THe oF twisting moment), then the machine member is said to be subjected to torsion ‘The stress set up by torsion is known as torsional shear stress. It ie sere at the cenercieal axis and maximum at the outer surface, Bending Stress is a more specific type of normal stress Compressive and tensile forces develop in the direction of beam axis under bending loads, These ferece induce stresses on the beam, known as bending stresses, POLY-DMEIntroduction to Machine Design DME.3 It has been observed that at any point in a strained material, there are three planes, mutually perpendicular to each other which carry direct stresses only and no shear stress. These perpendicular planes which have no shear stress are known as principal planes and the direct stresses along these planes are known as Principal stresses. In material science, fatigue is the initiation and propagation of cracks in a material due to cyclic loading. Once a fatigue crack is has initiated, it grows a small amount with each loading cycle, typically producing striations on some parts of the fracture surface. The fatigue limit or endurance limit is the stress level below which an infinite number of loading cycles can be applied to a material without causing fatigue failure. In material science, creep is the tendency of a solid material to undergo slow deformation while subject to persistent mechanical stresses. It can occur as a result of long term exposure to high level stresses that are still below the yield strength of the material. Factor of safety (FOS) is the ability of a systém’s structural capacity to be viable beyond its expected or actual load. Factor of safety are based on: consequences of failure. Previous experience, Accuracy of measurement of mechanical forces and material properties. : A stress concentration is a point in the part design where stress is significantly higher than in the surrounding area. Stress concentrations are most commonly caused by an abrupt change in the part’s geometry, typically around sharp corners, holes, notches or grooves. Short Answer Type Questions A. Choose the correct answer from the given alternatives in each of the following: 1. The adaptation of existing design of an item is termed as [WBSCTE 2012] (@) rational design (b) adaptive design (c) development design (d) none of these Answer: (b) 2, Mild steel belongs to the following category [WESCTE 2013] (a) low carbon steel (b) high carbon steel (c) medium carbon steel (d) alloy steel Answer: (a) 3. Factor of safety is the ratio of (WBSCTE 2013) (a) breaking stress to working stress (b) endurance limit to yield stress (c) elastic limit to ultimate stress (d) yield stress to working stress Answer: (a) POLY-DME=... ESIGN OF MACHINE ELEMENTS p DME.4 is caused due t0 - material from point to point ina member a i which loads on a member are applied nk 4, Stress concentratior (a) variation in properties 0} (b) pitting at points or areas a (c) abrupt change of section (d)all of the above “Answer: (4) 5, Factor of safety is the ratio of: pee (6) endurance limit to yield stress (a) breaking stress to working stress (elastic limit to ultimate stress Answer: (a) (@ yield stress to working stress 6 Which one of the following materials is highly elastic? [wescTE 2022) (a) Rubber (b) Brass (c) Steel (d) Glass Answer: (c) 4, The material in which large deformation is possible before the absolute failure or [WBSCTE 2022] fracture is called (a) elastic (b) plastic (c) ductile (d) isotropic ‘Answer: (¢) fits high [WBSCTE 2022] (b) endurance strength (d) compressive strength 8, Cast iron is used for machine beds because o! (a) tensile strength (c) damping capacity Answer: (d) 9. The endurance limit of a material with finished surface in comparison fo rough surface is [Model Question] (a) more (b) less (©) same (d) more or less depending on quantum of load (©) unpredictable Answer: (a) [Model Question] 10. The fatigue life of a part can be improved by (a) electroplating (b) polishing (c) coating (d) heat treating (e) shot peening Answer: (e) 11, Stress concentration in static loading is more serious in [Mode! Question] (2) ductile materials (b) brittle materials () equally serious in both cases (d) depends on other factors (e) unpredictable Answer: (b)Introduction to Machine Design DME.5 12, Endurance limit or fatigue limit is the maximum stress that a member can withstand for an infinite number of load applications without failure when subjected to [Model Question] (a) dynamic loading (b) static loading (c) combined static and dynamic loading _(d) completely reversed loading (e) all of the above Answer: (d) 13. Which of the following materials has maximum strength? [Model Question] (a) grey cast iron (b) plain carbon stee! (c)alloy steel (d) aluminium alloy Answer: (c) 14. Which of the following materials has maximum ductility? [Model Question] (a) grey cast iron (b) mild stee! (c)alloy steel (d) high carbon steel Answer: (b) 15. Grey cast iron contains [Model Question] (a) less than 0.3% carbon (b) 0.3 to 0.5% carbon (c) 0.5 to 1.4% carbon (d)3 to 4% carbon Answer: (d) 16. Medium carbon steel contains [Model Question] (a) less than 0.3% carbon (b) 0.3 to 0.5% carbon (c) 0.5 to 1.4% carbon (d) 3 to 4% carbon Answer: (b) 17. Steels used for welded assemblies are [Mode! Question] (a) medium carbon stee! (b) mild steel (c) high carbon steel (d)alloy steel Answer: (b) 18, Resilience of material is important when subjected to [Model Question] (a) wear and tear (b) shock load (©) inertia load (d) steady load Answer: (b) 19, Material used for bearing bushes is [Model Question] (a) phosphor bronze (b) gunmetal (c) Babbitt (d) any one of the above Answer: (d) POLY-DME— nik DESIGN OF MACHINE ELEMENTS OMEg 20. Die cast parts are used when @ material ofthe parts has low melting point Mosel Question (©) parts have small size () parts are made on large scale (@) all three objectives are desired Answer: (d) 21. Fibres used for fibre-reinforced-plastics are made of (a) ste! wires (b) hemp [Model Question (€) glass and carbon (d) asbestos Answer: (c) 22. Synthetic rubber is used for (a) V belt (b) gasket Mosel Question (c) seals (4) all three pants Answer: (d) 23. Toughness of stee! is increased by adding [Model a, (a) nickel (b) chromium (©) sulphur (@) tungsten Answer: (a) 24, Wear resistance of steel is increased by adding [Model Question) (2) nickel (b) chromium (©) sulphur (d) none of the above Answer: (b) 25. Hardness of steel is increased by adding [Model Question) (2) nickel (b) molybdenum (©) sulphur (d) none of the above Answer: (b) 26. In free cutting steel, important alloying element is {Model Question] (a) nickel (b) chromium (©) sulphur (d) tungsten Answer: (c) 27. A cast iron designated by FG300 is [Model Question] (a) grey cast iron with carbon content of 3% (b) grey cast iron with ultimate tensile strength of 300 N/mm? (©) grey cast iron with ultimate compressive strength of 300 N/mm? (d) grey cast iron with tensile yield strength of 300 N/ mm? Answer: (b) POLY-DMEIntroduction to Machine Design DME7 28. Plain carbon steel designated by 40C8 mieans (Mode! Question} (a) plain carbon steel with ultimate tensile strength of 400 N/mm? and 0.8% carbon (b) plain carbon steel with 0.35 to 0.45% carbon and 0.7 to 0.9% manganese (c) plain carbon steel with 0.8% carbon and 4% manganese (d) plain carbon steel with 40% carbon and 8% manganese Answer: (b) 29. The ultimate strength of stee! in tension in comparison to shear is in the ratio of [Model Question} (a)1:1 (b)2:1 (c)3:2 (2:3 (e)1:2 Answer: (c) B. Fill in the blanks in the following statements: 30. Steel contain upto 1 % of carbon, [WeSCTE 2013] 31. The ultimate strength of steel in tension in comparison to shear is in the ratio of £33. [WESCTE 2014) 32. Yield point in fatigue loading as compared to static loading is louder. (WESCTE 2014} 33. Factor of safety is the ratio of ultimate stress and working stress. (WBSCTE 2016} 34. A lead screw with half nuts in a lathe, free to rotate in both directions has square/acme threads. [WBSCTE 2016] 38. {sotropic materials have identical properties in all dimensions. [WBSCTE 2016) 36. The ratio between ultimate stress and working stress is known as factor of safety. The factor of safety for brittle material is 2 times that for ductile materials under static load condition. [wescTE 2017] 37. Bronze is an alloy of copper and tin. [WBSCTE 2017] 38. Lead and tin based alloys are used as solder metal. [wescTE 2017) 39. The maximum energy that can be stored in a body due to external loading upto elastic limit is called proof resilience. [WBSCTE 2017] 40. Leather is used for power transmission belting A [WBSCTE 2017] 41. Shock loads are also known as impact load. [wascTe 2017) 42. A hot short metal is brittle when hor. IWBSCTE 2017] POLY-DMEa nk DESIGN OF MACHINE ELEMENTS DME.8 43. The property of a material which enables it resist fracture due to high impact loads [WBSCTE 2017} is known as foughness. 444, Stress concentration in static loading is more serious in brittle materials. [WBSCTE 2017) 45. Isotropic are those which have the same elastic properties in all directions. [WBSCTE 2017] a mild steel specimen can be roughly predicted from brinell 46. Tensile strength of [WBSCTE 2017) hardness test. 47, The property of a material due to which it is progressively deformed 2% 3 slow rate with constant time is called creep. [WBSCTE 2018] 48, Stress concentration is defined as the localization of high stresses due to irregularities present in the component and abrupt changes of the crossect on [WBSCTE 2018] is the graphical representation of stress amplitude vs. the number of 49. The S-N curv [WBSCTE 2019} cycles before fatigue failure. 50. Toughness of material reduces when it is heated. [WBSCTE 2018} tance of the materials to fluctuating stresses is the 51. The phenomenon of decreased resist [WBSCTE 2019] main characteristic of fatigue failure. 52. The significance of 25C 12 SI4 is the specification (chemical composition) for carbon manganese and sulphur used free cutting steel [WBSCTE 2019] 53, Factor of safety is ratio of maximum stress/working or design stress. [WBSCTE 2019] that results in 54. Fatigue is the weakening of a‘material caused by cyclic loading [WBSCTE 2020] progressive and localized structural damage. 55. The stress level below which a specimen can withstand cyclic stress indefinitely without exhibiting fatigue failure is called endurance limit. [WBSCTE 2020} 56. The ratio of ultimate stress to working stress is called factor of safety (FOS). [WBSCTE 2020) 57. The stress concentration in a body happens because of sudden change in the geometry of the body due to cracks, sharp comers, holes or decrease in its cross ‘section area. [WBSCTE 2020] POLY-DMEeat. | er Introduction to Machine Design DME.9 58. Malteabitity is the ability of a material by virtue of which it can be flattened into thin sheets. IWBSCTE 2020} 59. As per IS: 1570, C 45 (or 45C8) steel will have a carbon percentage of 0.4 to 0.5%. 60. In design, aesthetic refers to the visual attractiveness of a product. [WBSCTE 2020) 61. To minimize stress concentration ‘fillet is provided in proper position in the ‘component. IWBSCTE 2022] 62. Creep in metal, plastics, rubber, concrete is the result of continuous tension and compression. [WBSCTE 2022] 63. Percentage elongation during tensile testis indicative of ductility. WBSCTE 2022] C. State whether the following statements are True or False: 64. In static loading, stress concentration is more serious in brittle materials. [WSSCTE 2013] Answer: True 65. Steel containing upto 0.15% carbon is known as dead mild steel. [WBSCTE 2013] Answer: True 66. The algebraic difference between the minimum limit of size and the corresponding basic size is allowance. [WBSCTE 2016] Answer: False 67. The basic shaft system is one whose both the upper and lower deviations are zero. [WBSCTE 2016] Answer: False 68. To minimize stress concentration sharp corner is provided in proper position in the component. (WSSCTE 2016, 2018} Answer: False 69. The material in which large deformation is possible before the absolute failure or fracture is called brittle material [WRSCTE 2016] Answer: False 70. Plastic is a metallic material. [WBSCTE 2017} Answer: False POLY-DMEnk DESIGN OF MACHINE ELEMENTS: DME.10 ai. When the material is loaded within elastic Timi then the stress is inversely jional to Strain. [WBSCTE 2017) Answer: False +72. Basic constituents of monel metals are nickel and e9PPEr [wascTE 2017) Answer: True 73. Toughness is the desirable property in parts subjected to shock and impact loads. [WBSCTE 2018) Answer: Trae ‘74, The shock resistance of steel is increased by adding chromium. [WBSCTE 2018) ‘Answer: False [Correct answer is nickel and chromium] [WBSCTE 2019} 175, Fatigue failure is time dependent failure. Answer: Trae +16. Malleability decreases with temperature while ductility increases with temperature Answer: False [WBSCTE 2019] D. Answer the following questions: 77, What do you mean by factor of safety? [WBSCTE 2014, 2015] “Answer: It is the ratio between the ultimate stress and working stress ‘78. Write the name of one impurity contains in the steel. [WBSCTE 2014] ‘Answer: Slag /Sulphur 79. At which point, the bending stress in a curved beam is zero? [WBSCTE 2014] ‘Answer: At neutral axis, the bending stress is Zero. 90. At which type of loading, the stress concentration is more serious in ductile materials? [WBSCTE 2014} Answer: Cyclic loading $1. What is ductility? [wascTE 2022] Answer: The physical property of metal that can be drawn into thin wire is called ductility or ductility is property of metal associated with the ability to be stretched into wire without breaking. 82. State Hooke’s law. [WBSCTE 2022] POLY-DME ai taiIntroduction to Machine Desian DME.11 Answer: According to Hook's law, body's strain is directly proportional to the applied force, if the applied force is within an elastic limit. wt Stress 2 Strain or, — SHESS Constant Strain 83. If d is the diameter of a shaft, then what will be the value of polar moment of inertia of its section? [wescte 2022} Answer: Polar moment of inertia, J = oe 84. In S.I. system what is the unit of stress? (WESCTE 2022) Answer: Pascal or N/m’. 85, Which type of threads are used in lead screw? (wascTE 2027] Answer: ‘Three of the most common types of threads used in lead screws are: Square thread, Acme thread, Buttress thread. 86. What is strain? [wescTE 2022] Answer: Strain is the amount of deformation experienced by the body in the direction of applied force, divided by initial dimensions of the body. Mathematically, strain, eZ or e= 2 where longitudinal strain, 5/is the change in length and so the original length and volumetric strain is change in volume to the original volume. 87. Draw the stress strain diagram for a ductile material and show the salient points. [WSSCTE 2022} POLY-DME|ACHINE ELEMENTS OFM. DME.12 [A= Proportional limit B= Elastic limit (C= Yield sess point E= Ubimate stress pont or beginning of neck formation F= Breaking stress point — sian — govern selection of material while designing a 88, Name any two factors that machine component. [WBSCTE 2022] Answer: : al are: (a) Availability: material should Two major factors that govern selection of materi: by Cost: material should be available at cheaper rate be available easily in the market, Long Answer Type Questions > 1. What is stress concentration? Where does it ‘occur? How could you minimize ~ it? Explain with necessary sketch. [WBSCTE 2011] Or, What are the causes of stress concentration? Explain the methods to reduce stress concentration. [WBSCTE 2016, 2018] Answer: cal shape, the simple stress "0 Whenever a machine part suddenly changes its geometri stress due to sudden change in longer remains the same but increases. This increase in geometrical shape is called stress concentration. Geometric discontinuities cause on object to experience a local increase in the intensity of a stress field. The stress concentrations occur near cracks, cross-sectional area of the object. It should also be noted that tool marks. Porosity in castings etc. may also give rise t stress concentration effect. High local stresses can cause the object to fail more quickly than if it wasn’t there. Engineers must design the geometrical shapes ‘of the objects to minimize stress concentrations. In many design situations, it is not possible to altogether avoid the effect of stress concentration, but it can be minimized by making logical changes in the design of the sharp comers, holes and, changes in the parts. 7 poLy-DMEIntroduction to Machine Desian DME.13 ‘Stress Concentration in a shaft due to ‘change in georetsical shape C= tl => oor Design Bener Design For example, a stepped shaft can be gradually reduced in diameter than abrupt reduction. Another example, to reduce one of the worst types of stress concentrations, a crack, is to drill a large hole at the end of the crack. The drilled hole, with its relatively large diameter, causes a smaller stress concentration than the sharp end of a crack. In mechanical design, stress concentration effects can be reduced by placing these geometric features in a non critical stress zone. > 2. Draw S-N curve for steels and show endurance limit on it. IWBSCTE 2016, 2019] Answer: S-Neurve In S =N curve, ‘S’ stand for “Stress” arising out of repetitive load and *N’ stands for “Number of cycles to failure”. The fatigue strength more appropriately termed the endurance limit is usually determined from a polished specimen subjected to reversed bending. y Stress amplitude S) — Range of sess which may be applied for ifinte 20 of mes lo 10? + Number ofeyetes N The graph mentioned above is an example of S ~ N curve. The line is downward-sloping. Where the endurance limit is shown. Endurance limit is the stress level below which a specimen can withstand cycle stress indefinitely without exhibiting fatigue faiture. But failure will occur often a diminishing number of cycles as the range increases above this POLY-DMEnX DESIGN OF MACHINE ELEMENTS DME.14 limiting value. The endurance limit for more of steels is found to be roughly half of the ultimate tensile stress. a) z 104s et 3 0 xy Fatigue Hint 5 & 200" 2014-T6 Aluminium f 100 107 10° 10" 10° 10 10" 10% 10" — Number of eyeles. Ny > 3. (a) What are the’common material used in mechanical engineering design? How can properties of steel be improved? [WBSCTE 2017, 2019] (b) State the reasons for the wide use of cast iron as an engineering material. What advantages are obtained by mixing nickel to C.I and steel? [WBSCTE 2017] Answer: a) The materials. used in mechanical engineering design for manufacturing of various products are broadly classified into two groups. 1. Metallic materials, 2. Non-metallic materials Metallic materials can be further split into ferrous and non-ferrous materials. Ferrous materials consist mainly of iron with comparatively small amount of other materials. Ferrous materials are iron and its alloys suh as cast iron, grey cast iron mnalleable cast iron, wrought iron and steel of low carbon content and high carbon content. Non-ferrous materials contain little or no iron. The materials are copper, zinc, tin, lead, aluminium. The alloys produced by combining non-ferrous materials are brass, bronze, gun-metal, duratumin etc. Non-metallic materials include plastics, rubber, leather, carbon, wood etc. There are three general ways to strengthen steel: i) Chemical composition condition: By adding carbon, Mangenese (Mn) and other alloying elements such as Nickel, Chromium, Molybdenum, properties of steel can be improved. The effect of various alloying elements added to steel are: Nickel: It increases strength of steel without decreasing ductility. Chromium: Increase strength and hardness of steel. Tungsten: It imparts hardness to steel and this hardness is retained even at high temperature (hot hardness). Molybodenum: It is used alongwith Cr and Mn to make alloy stee! highly tensile. Vanadium: It increases tensile strength and reduces brittleness of steel. POLY-DMEae Introduction to Machine Desian DME.15 ii) By mechanical working such as hot working and cold working: Hot working include forging, hammering, rolling etc. whereas cold working includes cold rolling, warm forging or cold swaging. When the processing temperature’ of the mechanical deformation of steel is above the re-crystallization temperature, the process is termed as hot working; otherwise it is cold working. In hot working process, the grain structure of the metal is refined and thus mechanical properties improved. Cold working improves strength properties of the steel. iii) By heat treatment of Steel: The best way of changing material property is to have heat treatment. Very few steel alloys will alter mechanical properties via any technique other than heat treating. b) The cast iron is the product of a furnace, called cupole furnace in which pig iron is charged along with coke and limestone. ‘The reasons for the wide use of carbon as an engineering material are: i) It is the cheapest among all other types of ferrous metals. It’s hardness is more than that of Mild steel and wrought iron. ) It possesses much wear resistance property iv) Its compressive strength is much more than that of Mild steel and wrought iron. v) It possesses good damping capacity. vi) Some kind of east iron has good machineability. vii) It can be cast almost to any size and form. Advantage of mixing nickel to C.1: Nickel is used in amount of 0.25% to 5% in low alloy cast iron. This promotes machinability of cast iron. In heat and corrosion cast irons as much as 35% nickel is used. “NI-Resist” a typical heat and corrosion resistant cast iron has a composition of 14% Nickel. “NI-Resist” can withstand a temperature of 800°C and is used in a wide variety of media such as hydraulic, sulphuric, chlorides, caustic, sea water etc. Advantages of mixing nickel to steel: It increases strength of steel without decreasing ductility. If this steel is subjected to case hardening, it produces better core than plain carbon steel. This steel has good corrosion resistance property. A nickel steel alloy containing 36% nickel is called ~Invar™ which is used for making measuring instruments and gauges. Invar has a negligible co-efficient of expansion. D4. Discuss the important non-metallic materials of construction used im engineering practice, (WBSCTE 2017) Answer: The commonly used important non-metallic materials are wood, glass, rubber, leather, carbon, plastics etc. which are used in various engineering construction. i) Wood: It is a bad conductor of heat and electricity. It is lighter in weight but has sufficient tensile strength. It has less resistance to corrosion. Wood is used in making patterns used in foundry. POLY-DMEINE ELEMENTS DME.16 nX DESIGN OF MACH! Glass is used in doors and windows. Glass i Glass: It is a very brite and hard material of special composition is used in various optical instruments. fily Rubber: Rubber and similar synthetic Make such as Neoprene have a variety of wher: machinery. Rubber should be protected from high temperature, oil and sunlight. Tt is an excellent material for seats ‘and diaphragms for water lubricated bearings, for parts subjected to vibrations. jap Leather: Leather is very flexible and has good , making gaskets, belts etc. Its also used 88 & packing material and in making washers. 4) Carbon: It has very high compressive ‘trength and high shear strength compared to Phere non-metallic materials. It has good resistanc®, corrosion. Carbon is used in ‘of carbon which is used in bronze used as a ‘Glectrical insulation. Graphite is a form fesicant in bearing material. Diamond is used for drill bits which are used for oil exploration, digging deep wells ete. $i Plasties: Plastics are lighter in weight but have high strength. It can resist corrosion Pratics are available in various colours and surface fi ish of plastic products is very good. There are two types of plastics such as (a) Thermoplastic plastics, resistance to wear. Leather is used in (b) Thermosetting plastics. D 5 State the sequence of events in system of design cycle (General procedure of machine design). [WBSCTE 2018} Or, What is the general procedure in machine design and explain it? [WBSCTE 2019] Answer: General Procedure in Machine Design: In designing a machine component, there is no rig! a eee mays. However, the general procedure to solve a design problen! is as follows: 1) Recognition of need. First of all, make a complete staterert of the problem, jedicating the need, aim or purpose for which the machine is to be designed. 3) 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 ‘energy transmitied 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 ooo used. It should be kept in mind that each member should not deflect or deform than the permissible unit. jd rule. The problem may be attempted each member of the machine and the POLY-DMEDME.17 Fig: General procedure in Machine Design : Modify the size of the member to agree with the past experience and judgment to facilitate of 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 process 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. When there are number of components in the market having the same qualities of efficiency, durability and cost, then the customer will naturally attract towards the most appealing product. The aesthetic and ergonomic, are very important features which gives grace and lusture to product and dominates the market. >. 6. What do you mean by endurance limit? (Mode! Question] Answer: Endurance limit: It is defined as maximum value of the completely reversed bending stress which a polished standard specimen can withstand without failure, foe infinite number of cycles (usually 10” cycle). It may be noted that the term endurance limit is used for reverse bending only while for other types of loading, the term endurance strength may be used when referring he fatigue strength of the material. It may be defined as safe maximum stress which can be applied to the machine part working under actual condition, id creep curve? [Model Question} > 7. What do you mean by creep strain POLY-DMEiE ELEMENTS DME.18 nk DESIGN OF MACHIN! Answer: Anam erjal science, creep (sometimes called cod flow) is the tendency of a solid material iledr the influence of mechanical stresses: It can to move slowly or deform ecu as a result of long term exposure 10 high levels of stress that are still below the Jield strength of the material. Creep is mow, Severe in materials that are subjected to heat eljong periods, and gene rally increases 35 they NN their melting point. The rate of deformation (strain) is @ function of the material properties, exposure time, exposure temperature and the applied structural load. Depending on the magnitude of the became so large that a component applied stress and its duration, the deformation may SP po longer perform its function ~ e.g. creep ‘ofa turbine blade will cause the blade ca oe act the easing, resulting in the failure of the blade. Creep is usually of concern fe under high stresses or high temperatures. Creep ‘Shen evaluating components that opera het Sormation mechanism that may or may not conse © failure mode. For example, ‘state creep in concrete is sometimes welcomed because: it relieves tensile stresses that might otherwise lead to cracking. Classical Creep Curve: The rate of deformation i called the eresP rate. Itis the slope of the line in a creep strain The relationship between the true stress-true strain diagram: POLY-DMEage Introduction to Machine Design DME.19 2 8. What are the design considerations to avoid creep failure? (Model Question) nswer: 1. Reduce the effect of grain boundaries by: (a) Use single crystal material with large grains. (b) Addition of solid solution to eliminate vacancies. 2. Employ materials of high melting temperatures. 3. Consult creep test data during material selection considering: (a) Type of service application . (b) Set adequate inspection intervals according to life expectancy. > 9. Discuss ‘Fatigue’ consideration in design of component. DModet Question} ‘Answer: Fatigue is a phenomenon associated with variable loading or more precisely to cyclic stressing or straining of a material. Just as we human beings get fatigue when a specific task is repeatedly performed, in a similar manner metallic components subjected to variable loading get fatigue, which leads to their premature failure under specific conditions. Fatigue loading is primarily the type of loading which causes cyclic variations in the applied stress or strain on a component. Thus any variable loading is basically a fatigue loading. A fatigue failure begins with a small crack, the initial crack may be so minute and cannot be detected. The crack usually develops at a point of localized stress concentration like discontinuity in the material, such as a change in cross-section, a keyway or a hole. Once a crack is initiated, the stress concentration effect become greater and the crack propagates. Consequently the stressed area decreases in size, the stress increase in ‘magnitude and the crack propagates ore rapidly. Until finally, the remaining area is tunable to sustain the load and the component fails suddenly. Thus fatigue loading results in sudden, unwarned failure. POLY-DME \lachine Parts Unit 2: Design of simple M: Unit at a glance: nnect rigidly two co-axial rods or ive forces. It is usually used in ‘cotter joint isa temporary fastening and is use 1960 ing steam engine, a piston rod tise which are subjected to axial tensile or compre conneting a Piston rod to the cross head of @ reciprocat cotits extension asa tal or pump rod, strap end of connecting rod ete. Following are the three commonly used cotter joints to connect two rods by a cotter. 1 Socket and Spigot cotter joint 2. Sleeve.and cotter joint 3. Gib and cotter joint. ‘A cotter isa flat wedge shaped piece of rectangular ‘cross-section and its width is tapered from one end to another for an easy adjustment. i knwekle joint is used to connect two rods which are under the attion of tensile loads. 4 Kamickle joint may be readily disconnected for adjustments Bt repair. Its use may be Fused in the link of a cycle chain, tie rod joint for roof truss, valve rod joint with eccentric rod etc Threaded fasteners are amor to the ease in which they can ng the most commonly used for assembling components due be installed and uninstalled as needed. There are three main types of threaded fastener, Bots, Serews and Studs. Screw fasteners can fail in several vores but the dominant stress in a screw under tension is tensile. Other potential failure modes of screws are stripping shear failure atthe thread roots and fatigue failure When the ordinary bolt is subjected to tensile force, there are iw distinct regions of strength. As the diameter of threaded portion is less than the shank diameter, the threaded portion is subjected to stress concentration. Therefore stress induced in threaded portion porn than the stress induced in the shank portion making the threaded portion as the vreakest part and the maximum amount of elastic energy is observed in this region. So eal bolt will be one which is subjected to the same stress level at different clis™- sacri in the bol. It is called the bolt of uniform strength. Hence in the bolt of sstform strength, the entire bolt is stretched to the same limiting value, thus resulting in ‘maximum energy absorption. The eye bolt (also known as lifting eye bi end. They are used for a wide variety of material lifting applicati or swivel. The securing eye must be securely attached to the structure before rope cables are tied for lifting. olt or eyelet) is a type of bolt with a loop at one ions and may either pivot oFDesign of Simple Machine Parts DME.21 Short Answer Type Questions ‘A. Choose the correct answer from the given altematives in each of the following: [WBSCTE 2015, 2021) 1. A cotter joint is used to transmit____ (b) axial compressive load only (a) axial tensile load only (c) combined axial and twisting loads (d) axial tensile or compressive loads Answer: (d) 2, The taper on a rectangular sunk key is- [WBSCTE 2021] (a) 1 in 16 (b) 1 in 32 (©) 1 in 48 (d) 1 in 100 Answer: (d) 3. The taper on cotter varies from [WBSCTE 2021] (a) Lin 15 to Lin 10 () 1 in 24 to 1 in 20 (©) Lin 32 to 1 in 24 (d) Lin 48 to 1 in 24 Answer: (d) 4. Which of the following cotter joint is used to connect strap end of a connecting rod- [WBSCTE 2021] (b) Sleeve and cotter joint (a) Socket and spigot cotter joint (4) None of these (c) Gib and cotter joint Answer: (c) 5. In designing a sleeve and cotter joint, the outside diameter of the sleeve is taken as- @sd (b)2.5d ©@3d (aad Where d = Diameter of the rod. [wescTe 2021] Answer: (b) 6. The length of cotter, in a sleeve and cotter joint, is taken as- [WBSCTE 2021] (@ sd (b)2.5d (3d @4d Answer: (d) 7. Fork end is the part of: [WBSCTE 2022] (a) coupling (b) pulley (c) cotter joint (A) knuckle joint Answer: (d) [Model Question] 8. A taper is provide for cotter (a) to ensure tightness in operating condition (b) to provide wedge action (c) to ease the removal of cotter during dismantling, (d) for all three reasons Answer: (d) POLY-DMEnk DESIGN OF MACHINE ELEMENTS DME.22 i .d and the cross head of steam engine is. 9. The joint between the piston rod and caiman (@) knuckle joint (b) universal joint (©) coter joint (d) key joint Answer: (©) [Model Question] ised for the joint between {@) piston rod and cross head of steam engine (b) Slide spindle and fork of valve mechanism (6) piston rod and tail rod or pump rod (@) for all three applications ‘Answer: (@) 10, Cotter joint is u 11. A knuckle joint is used to transmit [Mode! Question] (a) axial tensile force only (b) axial tensile or compressive force (c) axial compressive force only (4) combined bending and torsional moment Answer: (2) 12. The joint in valve mechanism of reciprocating engine is (a) knuckl (b) universal joint (c) cotter joint (d) key joint Answer: (a) [Model Question] [Model Question] (b) links in suspension bridge (@) for all three applications 13. Knuckle joint is used for the joint between (a) tie bars in roof trusses (©) fulcrum of lever and support Answer: (d) [Model Question] (b) torsional shear stress (d) axial compressive stress 14. The pin in knuckle joint is subject to (a) double shear stress (©) axial tensile stress Answer: (a) low it, the threads of bolt are [Model Question] (b) torsional shear stress (d) compressive stress 15, When a nut is tightened by placing a washer bel subjected to (a) direct shear stress (c) tensile stress Answer: (a) POLY-DMEDesign of Simple Machine Parts DME.23 16. When the shear strength of nut is equal to the tensile strength of bolt, the height of niut(h) should be [Model Question} (a)h=05d, (b)h=0.25d, (h=0.75d, (@a=d, where d, = core diameter of threads. Answer: (a) 17. The shock absorbing capacity of a bolt can be increased by , [Mode! Question] (a) increasing shank diameter (b) making shank diameter equal to core diameter of threads (c) using castle nut in place of ordinary hexagonal nut (d) using a washer Answer: (b) 18. The resilience of a bolt can be increased by [Model Question] (a) increasing shank diameter (b) increasing length of shank portion of bolt (0) increasing core diameter of threads (@) using a washer Answer: (b) [Model Question} (b) more than the nut size (d) independent of the nut size 19. The inner diameter of washer is (a) equal to the nut size (c) less than the nut size Answer: (c) 20, When the shear strength of nut is half the tensile strength of bolt, the height of nut(h) should be [Model Question] (@h=05 d, (bh=0.25 d, ()h=0.75 d, (@h=d, where d= core diameter of threads Answer: (b) 21, Standard coarse threads are equally strong in failure by shear and failure by tension, if the height of nut is [Model Question] fayhO.4d (b)h=0.6 d ()h=0.5d @h=d where d is nominal diameter of threads Answer: (a) POLY-DMEoo a DME.24 | nk DESIGN OF MACHINE ELEMENTS 22. The resultant axial force on bolt depends upon [Model Question} (a) initial tension (b) external applied load {stiffness of bolt and parts held by bolt (d) all three factors Answer: (4) 23. A self-locking screw has [Mode! Question (a) fine threads (b) coarse threads (c)two nuts {G) coefficient of fretion more than tangent of lead angle Answer: (4) B. Fill in the blanks in the following statements: . po: rcnuckle joint by means of cotter and # SBA Din TWESCTE 2010} 35, In sleeve and cotter joint, each cotter is in double shear- [WBSCTE 2019) [WaSCTE 2012] 26. The amount of taper for the cotter varies from | in 48 to 1 in 24. rod to the connecting rod [WBSCTE 2012] 27, A cotter joint is used for connecting piston 28, A knuckle joint is also known as forked pin joint. 29. Cotter of a cotter joint is treated as a simply supported beam. ed by shear. [WBSCTE 2012) [WBSCTE 2012) 30, The failure of pin in knuckle joint is likely to be caus [WBSCTE 2013, 2022} ter used in socket and spigot cotter joint is 2b>t- [WBSCTE 2013) 31. Shear resisting area of cot the thickness of cotter] [where b is the width and tis t 432. Ina metric thread designated by M40x3, the number 40 and 3 specify that the thread has nominal diameter and pitch in mm. [WBSCTE 2013] 33. The fastening devices having both ends threaded is called stud. [WBSCTE 2013] 34. A knuckle joint may readily disconnected for adjustments or repairs. [WBSCTE 2014] | 35. The draw of cotter need not exceed 3 mm. [WBSCTE 2014] 36. Stud is the fastening devices which has its both ends threaded. [WBSCTE 2016) Pol Y-DMEDesign of Simple Machine Parts DME.25 37. A washer is generally used to provide greater load bearing area. [WBSCTE 2016) 38. Square thread is used for power transmission. (WBSCTE 2017] 39, BSW threads have the angle equal to 55°. [WBSCTE 2017) 40. Taper of cotter varies from 1:48 to 1:24. [WBSCTE 2017] 41. Cotter joint, is usually connected a piston rod to the cross head of a steam engine. [WBSCTE 2018, 2019} Cotter joint is used when the merhbers are subjected to tensile or compressive type of 42. stresses. [WBSCTE 2019] 43. A cottor joint is used to connect two co-axial rods. [WBSCTE 2020] 44. Uniform strength bolt.is made by reducing the diameter of the shank of bolt corresponding to that of its minor diameter. ([WBSCTE 2020] 45. Ina bolt if the shank is turned down to a diameter equal to the diameter of the root of the threads is called the bolt of uniform strength. [WBSCTE 2022] C. State whether the following statements are True or False: 46. The cotter is uniform in thickness but tapered in width on one side. The normal value of this taper is 1 : 5 [WBSCTE 2013] Answer: False 47. Calculation of the diameter of the rod which are fastened by knuckle joint are made by considering failure of the rod in tension. IWBSCTE 2013} Answer: True 48. In a steam engine, the valve rod is connected to an eccentric by means of a knuckle joint. [WBSCTE 2015] Answer: True 49. Knuckle joint is used for connecting the piston rod and cross-head in a steam engine. [WBSCTE 2016] Answer: False 50. Multiple thread screws are used when quick motion is not needed without exerting much force. [WBSCTE 2016] Answer: True POLY-DMEnt DESIGN OF MACHINE ELEMENTS DME.26 [WBSCTE 2017) 51. A knuckle joint provides two degree of freedom. ‘Answer: False i i is shead by means of 2. Ina steam engine the piston rod is usually connected to the ros < knuckle joint. IWBSCTE 2017) Answer: False fts, which transmit torque. 153, A knuckle joint is unsuitable for two rotating shal [WBSCTE 2019) Answer: False $4. In a steam engine the valve rod is connected to an eccentric by means of a comer [WBSCTE 2019} joint, Answer: False D. Answer the following questions: 55, Which joint is usually used in connecting a piston rod fo the cross head of a steam engine? [WBSCTE 2014, 2015] Answer: Cotter joint 56. What are the different parts of a knuckle joint? [WBSCTE 2022] Answer: {@) Two eye end or fork end, (b) One eye end, (c) knuckle pin. Eye is formed on one of eae cad fork is formed on the other. Eye fits inside the fork and the pin is passed through both fork and eye. 57. Write the name of fastening device, which has its both ends threaded. [WBSCTE 2022] Answer: . Studs are fasteners with both its ends are threaded. 58, When nut is tightened by putting a washer what type of stress is induced in bolt? ; [WBSCTE 2022] Answer: | Bolts are always subjected to tensile stress when nut is tightened. | , if the load acting on it is 60 KN and [WBSCTE 2022] 59, Find the diameter of rod in a knuckle j Jf, =45N/mm?? Answer: Considering the failure of rod in tension load, 2 Patd? aes, POLY-DMEDesign of Simple Machine Parts DME.27 or, 60000 = Fa" «45 _ 60000%4 a = 7x45 or, — d=41.2mm > 1. Design a knuckle joint to withstand maximum pull of 25kN. Given data: f, 56 Nimm’, f, = 40 N/mm’, f.= 70 N/mm?, Determine - (i) dia. of rod, (ii) dia. Of pin, (iii) outer dia. of eye, (iv) thickness of single eye end. IWBSCTE 2008] Answer: Given, Pull, P= 25KN = 25000 N Tensile stress, o, = 56 N/mm? Shear stress, 7, = 40 Nimm? Crushing stress; o, = 70 N/mm? Assuming bending stress, 0, = 140 n/mm? = 1697.65 (i) Diameter of rods Let, d= diameter of rods. Considering the failure of rod in tension we know that, = 23.84% 24 mm (say) Therefore, the diameter of rods is 24mm. : Now the various dimensions of the Knuckle joint are fixed empirically as follows: (a) Diameter of knuckle pin, d, =d =24mm (b) Diameter of pin head & collar =1.5d (©) Thickness of pin head & collar, 1 =0.Sd =0.5x24=12mm (d) Length of taper pin, ¢=1,7Sd =1.75x24= 42 mm (©) Outside diameter of fork end d, = 2d = 2x24 = 48mm (f) Thickness of fork end 1, = 0.7Sd = 0.75x 24 =18mm (g) Outside diameter of single.eye end, d, = 2d = 2x24= 48mm (h) Thickness of single eye end, 1, = 1.25d = 1.25 x 24 5x24=36mm POLY-DMEDME.28 DESIGN OF MACHINE ELEMENTS Now checking for the safety of the all the above elements (Gi) Failure of knuckle pin in shear ‘The knuckle pin is in double shear | . parti xo, or, 25000 =2x(24)' xe, 4 p2<— og, = 2500 -27,63 Nim? 2xax576 i) Failure of the forked end in tension Fig: Knuckle Pin “Tearing Arca Fig: Fork end of the joint POLY-DMEDesign of Simple Machine Pé DME,29 P=(d,-d,)x2,xo, or, 25000 =(48-24)x2x18xo, 25000 0, = = 28.94 N/mm? 24x 2x18 (iv) Failure of the forked end in shear P =(d; -d,)x2t,xo, or, 25x10" =(48-24)x2x18x0, 25000 =~ = 28.94N/mm? 24x 2x18 or, 3, (v) Failure of the forked end in crushing P=d,x2,xo, a E of, 25000 =24x2x18x 9, po = 1, = 08. 94NN/mm? 24x2x18 (vi) Failure of the eye end in tension 30 648 Tearing Area Fig: Eye end of the joint P=(d,-d,)xt, xo, or, 25000 = (48 - 24) x30x 0, 25000 —— =34.72N/mm?* 24x30 POLY-DMEnt DESIGN OF MACHINE ELEMENTS DME.30 (vii) Failure of the eye end in shear P=(d,-d))xhxo, or, 25000=(48-24)x30x0, ng, = 25000 + 34%30 =34,72N/mm? (viii) Failure of the eye-end in crushing: P=d,x,Xo, or, 25,000 = (24x30)xo, | 25,000 _ 354.7 Nim? or, o, 24x30 From above, checking against each elements of the knuckle joint, we find that the different stresses induced are within permissible limit. Therefore. the design of the joint is safe. D2. A cotter joint supports a load varying from 40KN tensile to 40 kN of the rods, (ii) inside diameter of the socket, compressive. Design — (i) (iii) thickness of cotter. Take f; = 50 N/mm’, f, = 35 N/mm’, f. = 90 N/mm. [WBSCTE 2008] Answer: Given, Load on joint, P = 40kN Tensile stress, f, = 50N/mm? Shear stress, f, =35 N/mm? Compressive stress, f. = 90N/mm? | (i Calculation of diameters of rods | Let, d= diameter of rods | POLY-DME |Design of Simple Machine Parts DME.34 Considering the failure ofthe rod in tension across section X-X ‘We know that force ated xf n or, 40x10? =—xd? x50 10000 4 as OSD vd = 1018.59 =31.92mm *32mm (i) & (ii) Calculation for diameter of spigot (inside diameter of the socket) and thickness of cotter : Let d, = diameter of spigot or inside diameter ofthe socket 1= thickness of cotter, empirically, wo Considering the failure of the spigot in tension across the cotter hole, We know that force, Fig: Cross-sectional view ff (a,)° athe ‘of spigot with cotter or, 40x10" fds 4 or, 40x10? = i d= Sho or, 0000 = (3.14-1)x50 » 400004 2.14%50 2d, = 1495.33 = 38.66 mm = 40mm (say) + Inside diameter of socket = outside diaineter of spigot = d, = 40mm or, d? = Therefore, the thickness ofcoter, = 2 =10mm Checking for the induced crushing stress in the spigot or cotter, we know thatthe force Padxixf, or, 40x10" = 40x10x f, 40000 100.N/mm? POLY-DME| DME.32 nx DESIGN OF MACHINE ELEMENTS tress in the spigot or cotter is more than the permis: 1 its diameter (d,) sible limit Since the induced crushing s (i.e., 90 Nimm?); therefore, we have to reconsider Equating, force, P=d,xtxf, or, 40x10" =dyx 2x90 or, d? = 1000*4 - 1777.78 90 = 42.20 mm = 44mm (say) Baim 4 Therefore, thickness of cotter, D 3. A cotter joint supports a load varying from 25kN compressive to 25 KN tensile, Allowable stresses are f, = 50 N/mm’, f, = 35 Nimm’, f. = 80 N/mm’. Design - () the diameter of the rods, (ii) diameter of the spigot, and (ii) thickness of the cotter. [WBSCTE 2009} Answer: Given, Load on joint, P = 25 kN Tensile stress, f, = 50N/mm? Shear stress, f, = 35 N/mm* ‘Comprehensive stress, /f, = 80N/mm* (i) Calculations for diameters of rods Let, d =diameter rods Considering the failure of th We know that force ap potnd’ xf, | rod in tension across [section X-X fig. (i)] ie 1 i T or, 25x10" = xd" x50 | 250004 #x50 ’ cd = V636.62 = 25.23 = 26mm (say) Fg: @) Cotter ols i) Calculation for diameter of spigot and thickness of eotter [fi Jiameter of spigot and _+ + i or, d? = | Gi) & Let, d, 1 =thickness of cotter, empirically, rot the spigot in tension across the cotter hole, [Section Y-Y, fig. ()] POLY-DME Consider the failure ofBs im P: DME.33 We know that force, [Bay -axehe 2 or, 25x10" -[z4 Shao @ or, 25000 =7-(3.14-1) x50 Fig: (ii) 25000%4 2 25000%4 on t= 14x50 <.d, =V934,38 = 30.57mm = 32mm (say) 32 Therefore, the thickness of cotter, ¢ =~ =8mm (say) 4 Checking for the induced crushing stress in the spigot or cotter, we know that the force P=d,xtx f. or, 25x10° =32x8x f, 25000 _ 97.66 N/mm? 2x8 Since the induced crusting stress in the spigot or cotter s more than the permissible limit (i.e., 80 N/mm’); we have to reconsider its diameter (d,) . Equating force, P=d, xt f, or, 25x10° =d, «40 ae a =1250 2d, =38.35mm =36mm (say) Therefore, thickness of cotter, t = 3. 9mm (say) > 4. A knuckle joint is required to withstand a tensile load of 20 kN. Design the joint for — (i) dia. of rod, (ii) dia. of knuckle pin, (iii) onter dia. of eye and ») thickness of fork. Take f, = 55 N/mm’, f, = 40 N/mm? and f. = 70 N/mm’. [WBSCTE 2009, 2017] Answer: Given, Pull, P=20kN =20000N Tensile stress, o, = 55N/mm? Shear stress, ¢, = 40 N/mm? Crushing stress, 0, = 70 N/mm? POLY-DMEDESIGN OF MACHINE ELEMENTS DME.34 Hl x55 Taking next standard higher diameter as 22 mm. ‘Therefore, the diameter of rods is 22mm. ‘Now the various dimensions of the knuckle joint are fixed empirically as follows: =22mm a) Diameter of pin, d, b) Diameter of pin head and collar = 1.5d =1.5x22=33mm ©) Outside dia. of the fork end, d, = 2d =2x22= 44mm 4d) Thickness of the fork end, f, = 0.75d =.75x22=16.5mm=17mm e) Thickness of single eye end, f, =1.25d =1.25x22=27.5= 28mm f) outside dia. of the single eye end, d, = 2d =2x22= 44mm Now, checking the safety of the all the above elements: i) Failure of knuckle pin in shear 1 P=2x4d? xo, 4 or, 20000 = «Fx (22) x9, 20000% 4 96.30Nimm? 2x ex 484 i) Failure of fork end in tension =(d,-4,) x1,x2xo, or, 20000 =(44-22)x2x 0, x17 20000 _ _26.73N/mm? ~2x22x17 i) Failure of fork end in shear P=(d,-d,)x1,x2o, or, 20000 =(44-22)x17x2xo, 20000 or, o, =———— = 26.73 Nimm* BeiTxa O73 Nmm on, o, or, 0, POLY-DMEDesign of Simple Machine Parts DME.35 iv) Failure of fork end in crushing P=d,x4,x2xo, or, 20000 = 22x17x2xo, 20000 A 08 8, = gag BAS Nem v) Failure of eye end in tension: P=(d,-d,)xt,xo, or, 20000 = (44-22) x 28xo, 20000 22x28 vi) Failure of the eye end in shear: P=(d,-d))xt, x0, 20000 22x28 vii) Failure of the eye end in crushing: P=d,xt,x@, or, 20000 = 22x 28x, 20000 or, 0, = * 22x28 From above, checking against each elements of the joint, we found that the different stresses indeed are within permissible limit. = 32.46 N/émm? or, 0, = = 32.46 N/mm? = 32.46 N/mm? D5. Design a cotter joint for connection two MS rod of equal diameter transmitting an axial load of 450kN. The material of the cotter and rods will permit the following stresses — Tensile Stress = 65 N/mm’. Shear Stress = 50 N/mm’. Crushing Stress = 100 N/mm*, IWBSCTE 2011) Answer: Given, Force transmitted, P = 450kN = 450 x 10°N Tensile stress for M.S. o, = 65 N/mm? Shear stress for M.S. o, = 50 N/mm? Crushing stress for M. o, =100N/mm? POLY-DMEni DESIGN OF MACHINE ELEMENTS DME.36 re od Fig: Rod with Spigot (® Diameter of the rods Let d= diameter of the rod : Considering the failure of the rod in tension across section xx: i We know, paid’. o, or, 450x10? =2 xd? x65 mae 4 Fig: Cross-section of spigot with cotter = 93.89 =94mm (say) (ii) Diameter spigot or inside dia of the socket and thickness of cotter Let d, =dia. of the enlarged and of the rod and = thickness of the cotter As per recommendation, f =4; Considering the failure of the spigot in tension across the cotter hole. x P [24 aaa of, 450%10° [2a az a x or, 450% 10° -[24 - 4,2 Jess POLY-DME. Design of Simple Machine Parts DME.37 2 or, 450x10° -[$ou- iss] 45010 x4 214x65 dy = 1294033 =113.76~114 mm (say) [As per recommendation this diameter should be 1.25d Therefore, taking d, =1.25%94=117.5~120mm or, d3 = ‘Therefore, thickness of the cotter, ¢ = 120 — 30 mm Checking for the induced crushing stress in the rod or cotter. . We know the P=d,x1xo, or, 450%10? =120x30xa, _ 450%10° ~ 12030 Since the crushing stress is more than the permissible limit; therefore, we have to reconsider the thickness of the cotter as well as diameter of the spigot. P=d,x1xo, =125N/mm? or, 450%10 = dx 100 P x: d= SOO <4 F78000 = 134.16 ~135 mm (say) 100 Therefore, thickness of the cotter = 4 = Bs =33.75=34 mm (say) (iii) Outside diameter of the sleeve Let d, = dia, ofthe sleeve Considering the failure of the sleeve in tension across the cotter hole. We know that, Epp _ ae [Se ~43)-(d abt, or, soni =[2(e =135) (4 -139)34] 65 or, 6923.1=0.79d? ~18225~34d, +4590 or, 0.794? ~ 34d, - 20558.1=0 43.04d, ~26022.9=0 Fig: Cross-section of sleeve POLY-DMEDESIGN.OF MACHINE ELEMENTS DME.38 As per recommendation this diameter should be 2.5d Therefore, taking d, = 2.5d =2.5x94=235mm. (iv) Width of the cotter Let b = width of the cotter m—a Considering the failure of the cotter in shear. Since the cotter is in double shear. P=2xbx34x50 45010" b= yan sp 713235133 mm (say) _ Therefore, width of the cotter, 6=133mm Length of the cotter, ¢= 4xd = 4x94 =376 mm. Fig: Cotter pin > 6. Why the cotter of a cotter joint is made tapered? Why clearance is kept in a cotter joint and on which side? [WBSCTE 2011] Answer: The cotter of a cotter joint is made taper to facilitate its driving into position and its withdrawal from the joint at the time of dismantling the joint. It also helps to adjust the joint afterwards when required. A clearance which varies between 1.5 mm to 3 mm is provided on the taper side of the cotter. When the cotter is driven in, the clearance facilitates the cotter to force the rod more inside the spigot and make the joint perfectly tight. It should be noted that a similar clearance his between plain side of the cotter and rod to the joined. > 7. Where is the knuckle joint is used? What are the advantages of knuckle joint over cotter joint? [WBSCTE 2011] Answer: . A knuckle joint is used to connect two rods or bars, subjected to tensile load. It may be readily connected or disconnected for adjustment or repairs. The knuckle joints are very common is machines and structure. Advantages of Knuckle joint over cotter joint are as follows: i) The rods whose axes are not in alignments but meet in a point can be joined. ii) The joint allows a small angular movement of one rod relative to other. iii) It is specially designed to withstand tensile loads. iv) It can be easily connected and disconnected. v) It is capable of transmitting rotary and transverse motions. POLY-DMEDesign hine P: DME.39 > 8. Design the socket and the cotter for a cotter joint to support a load of 60 kN in tension and 60 KN in compression. The material used for the rods is Fe E 320 (yield stress = 320 N/mm). The load is applied statically. Take factor of safety as 4 [WBSCTE 2012] Answer: Given, Load on the joint, P = 60 kN Yield stress = 320 N/mm? Factor of safety = 4 Therefore, tensile stress, o, = 2. 80 N/mm? ‘Assume, crushing stress, 0, = 120 N/mm? and shear stress, o, = 50 N/mm? Calculations for the diameters of rods [Fig. ()] Let d= diameter of rods considering the failure of rods in tension across [Section x-x Fig. @) We know that force = P=2xd? xo, 4 or, 60x10! =4 xd? x80 60000 x4 7x80 d= /954.93 = 30.90 =31 mm (say) Ans. or, d® Calculations for diameter of spigot and thickness of cotter [Fig. (i)] Let d, = diameter of spigot and 1= thickness of cotter, empirically, =a Considering the failure of the spigot in tension across the cotter hole, [Section Y-Y, Fig. Gi) POLY-DME,DESIGN OF MACHINE ELEMENTS or, or, Fig: Gi) or, (3.14=1)x80 600004 2 on BZ 14x80 .s.d, =V1401.87 =37.44mm = 40mm(say) «= Inside diameter of socket = outside diameter of spigot = d, = 40 mm ‘Therefore, the thickness of cater, ‘=42=10mm Checking for the induced crushing stress inthe spigot or cotter, we know that the force ~ P=d,xtxo, or, 60x10? =40x10x0, = £0000 _ 150mm? 40x10 ; : got or cotter is more than the permissible limit Since the induced crushing stress in the spi (ie, 120 N/mm?); therefore, we have to reconsider its diameter (4). Equating, force, P=d,x1xo, or, 60x10 =dx 4x10 or, 2 = 2200*4 _ 9000 120 od, =44,.72mm = 45mm(say) Therefore, thickness of cotter, ¢=— =| 1.25mm =12mm(say) POLY-DMEDesign of Simple Machine Parts DME.41 Width of Cotter: Let 6 = width of the cotter considering the failure of the cotter in shear. Since the cotter is in double shear, P=2xbxtxo, mn 60x10" =2xbx12x50 P 2.b=50mm Therefore, the width of cotter, b = 50 mm fa or, Fig: (iii) Outside Diameter of the Socket: Let d, =outside diameter of the socket. Considering the failure of the socket in tension across the'cotter hole, We know that, [Flat aNd.) 60x10? -[Ee -45*)(d, =45)at2 a0 or, 750 =0.79d3 ~ 1590.43 12d, +540 or, 0,79d3 ~ 12d, - 1800.43 = 0 or, — d3 -15.19d, ~ 227 15.194)(15.19)° +4x1x2279 Wis ie = Fig: (iv) or, 7 7 2x! 9+95.68 =55.93mm (taking positive value) As per recommendation this diameter should lie between 1.75d to 2d. Therefore, taking, d, = 2d = 2»31=62 > 9% Design a knuckle joint for connecting two MS rods of equal diameter to transmit 250 kN. The material of the knuckle joint will permit the following stresses-Tensile stress = 75 N/mm’, shear stress = 60 N/mm?, crushing stress = 150 N/mm’. [WBSCTE 2013] Answer: Given, Pull, P = 250 kN = 250000 N Tensile stress, o, = 75 N/mm? Shear stress ¢, = 60 N/mm? Crushing stress o, = 150 N/mm? i) Diameter of rods: Let d= diameter of rods. POLY-DMEnk DESIGN OF MACHINE ELEMENTS: Considering the failure of rod in tension, we know ‘that, ° a? x75 or, fax ad = [250000%4 65,14 66 mm (say) axT5 Taking next standard higher diameter as 66 mm. Therefore, the diameter of rods is 66 mm. DME.42 Now the various dimensions of the Knuckle joint are fixed empirically as follows: a) Diameter of pin, d, = d = 66mm b © Thickness of pin head and collar, = 0.5d = 0.566 =33mm 4) Outside diameter of fork end d, = 2d =2x66=132mm ) Thickness of fork end, 1, =0.75d = 0.75 x66= 49.5 = 50mm f) Outside diameter of single eye end d,2d = 2x66 =132mm 8) Thickness of single eye end r, ii) Failure of Knuckle pin in shear: The knuckle pin is in double shear »P=2x2d? xo, 4 or, 250000=2 «4 (66) xo, 250000 4 = 36.54Nimm* 2x 1x 4356 iii) Failure of the Forkend in tension: P=(d,-d,)xt,x2xo, or, 250x110? = (132-66) x50x2xo, _.250%10" = 37.88N/mm* 66x 50x2 iv) Failure of the Forkend in shear: P=(d;-d,)x2xo, of, 20x10? =(132-66)x2x50xo, __250000 =———- = 37.88N) - a Diameter of pin head and collar =1.Sd =1.5x 66 =99mm = 100mm(say) 1.25d =1.25x 24 =82.5~80mm poe] pa Fig. (i) POLY-DMESim hine P: DME.43 v) Failure of the eye end in tension: P=(d,-d,)xt, x0, or, 250x10" =(132-66)x80x0, 250000 —— =47.34Nimm? 66x80 vi) Failure of the eye end in shear: P=(d,~d,)xt, xo, or, 250x10" =(132-66)x80xo, 250000 = 47.45N/mm? "66x80 vii) Failure of the eye end in crashing: P=d,xhxo, or, 280x110" = 66x80x0, 0, 2 satis? «66x80 From above, checking against each element of the knuckle joints, we find that the different stresses induced are within permissible limits. Therefore, the design of the joint in safe, > 10. Two rod ends of a Pump shaft are joined by means of a cotter, spigot and socket at the ends. Design the joint for an axial load of 100 kN which alternately changes from tensile to compressive. The allowable stresses for the material used are 50 N/mm’ in tension, 40 N/mm? in shear and 100 N/mm? in crushing. IWBSCTE 2014, 2019] Answer: Given, Load on the join, P= 100 kN . Tensile stress, o, = 50 N/mm? Shear stress = 40 N/mm? Crushing stress, o, =100N/mm* Calculations for the diameters of rods (Fig. (i)] Let d= diameter of rods. Considering the failure of rod in tension across [Section x-x Fig. (i)] We know that force P=2xd'xo, 4 POLY-DMEDME.44, nx DESIGN OF MACHINE ELEMENTS or, 100x10? = xd? x50 4 or, dg? = 100000x4 4x50 sod = V254648 = 50.46 = $2mm(say) Fig. Calculations for diameter of spigot and thickness of cotter [Fig. (i)] Let d, =diameter of spigot and = thickness of cotter, empirically, ¢= 4 Considering the failure of the spigot in tension across the cotter hole, [Section Y-Y. Fig. Gi] We know that force, [staat fee YY K x 4d, Ir, x10? =| =d? —d, x=+ |x 50 ae or, 100 x 10° [44 fi 4] * "> : ig. Gi or, 100x10? =| 24; a | .50 4 4 a or, 100000 = 4-(3.14 ~1) x50 100000 x 4 . or, j2 = 100000%4 2.14%50 wd, =J3738.32 = 61.14mm = 62 mm (say) .. Inside diameter of socket = outside diameter of spigot = d, = 62mm Therefore, the thickness of cotter, ¢ = 2 =15.5 ~16mm(say) Checking for the induced crushing stress in the spigot or cotter, we know that the force ~ P=d,xtxo, POLY-DMEn of Simple Maci DME.45 or, '100x10? =62x16xo, 100000 6x16 Since the induced crushing stress is more than the permissible limit (i.., 100 Nfinm?) We have to reconsider the diameter d, . 100.8N/mm? Equating, P =d,xtxo, ot, 10010? =d, 16100 =62.5mm = 63mm ‘Therefore, thickness of cotter, ¢ = 2 =15.75mm=16mm Width of Cotter: Let b= width of the cotter; considering the failure of the cotter in shear. Since the cotter is in double shear P=2xbxtxo, or, 100x 10? =2xbx16x40 -b=78.125mm = 80mm(say) i Therefore, the width of cotter, b = 80 mm Outside Diameter of the Socket: Let d, = outside diameter of the socket. Considering the failure of the socket in tension across the cotter hole, We know that, [Ela at) (2h -a)at fo, or, 10010" =[£ (4! ~63)~(4,~63)«16} a0 or, 2500 = 0.79d3 ~3969 - 16d, +1008 Fig: Gv) or, 0.79d; ~ 16d, -5461=0 or, d; ~20.25d, ~6912.6 =0 20.25 + (20.25)" +4x1x 6912.6 or, d, _ 20.25 +1674 2x1 = 93.82mm = 94mm (taking positive value) As per recommendation this diameter should lie between 1.75d to 2d. Therefore, taking, d, =1.75d =1.75x52=91mm Considering, d, = 2d POLY-DMEDESIGN OF MACHINE ELEMENTS: DME.46 nk or, d, =2x52=104mm Considering all the aspect, we can assume, d, = 94mm. MS rod of equal diameter to > 11. Design a knuckle joint for connecting two fhe following transmit 300 kN. The materials of the knuckle joint will permit tl stresses-tensile stress = 80 N/mm’, shear stress = 60 N/mm? and crushing stress = 150 N/mm’, [WascTE 2015) Answer: Given, Pull, P =300kN =300x10°N Tensile stress, o, =80N/mm* Shear stress, o, =60N/mm?* Crushing stress, ¢, =150N/mm? i) Diameter of the rod Let d= diameter of rods. Considering the failure of rods in tension, we know that P ie xo, or, 30x10" “ie x80 or, 2 = 300104 | 4774.03 ax or, d = 69.05mm = 70mm therefore, the diameter of rods is 70 mm. now, the various dimension of the knuckle joints are selected empirically as follows: a) Diameter of pin, d, =d = 70mm b) Diameter of pin'head =1.5d =1.5x70=10Smm ¢) Thickness of pin head, t =0.5d =0.5x70=35mm 4) Outside diameter of the fork end, d, = 2d = 2x70 =140mm €) Thickness of forkend, f, = 0.75d = 0.75 x70 = 52.5mm = 53mm f) Outside diameter of single eye end, d, = 2d = 2x70=140mm 2) Thickness of single eye end, f, =1.25d =1.25x70=87.5mm = 88mm Now checking for the safety of all the above elements for which dimensions are assumed. ii) Failure of knuckle pin in shear: AS the knuckle pin is in double shear, P=2x4d) xo, or, 300.10? = 2x x(70)' xo, POLY-DMEian le Machi DME.47 300x10° x4 2x2 x 4900 iii) Failure of the forkend in tension P=(d, -d,)x2t,xo, 300%10° = (140-70) x 2x53x0, 30x10" 70x 2x53 iv) Failure of the forkend in shear: P=(d,-d,)x2,xo, 30010? =——————_ = 40.43N/mm? 49-70) «2x33 a v) Failure of the forkend in crushing: = 38.97 N/mm? =39N/mm? = 40.43N/mm? P=d,x24,x0, or, 30010? = 70x2x53x0, 30x10? = = 40.43N/mm? Me Tax 55 Lise vi) Bearing strength of the pin (failure of the knuckle pin against crushing) Pao, xd, xt, of, 30x10" =o, 70x88 = 200410" _48.70Nimm" 70x88 vii) Failure of the eye end in tension (tearing strength of the single eye) P=(d,-d,)xt,xo, or, 300x10? =(140-70)x88x0, 30010” a= 70x88 Failure of the single eye end in shear P=(d,-d,)xt,xo, or, 300x10? =(140-70)x88xo, 0, = SOHO 48. 70mm? 70x88 From above, checking against each elements of the knuckle joint, we find that the different stresses induced are within permissible limit. Therefore, the design of the joint is safe, = 48.70 N/mm? POLY-DMEnk DESIGN OF MACHINE ELEMENTS DME.48 D 12. a) Itis required to design a knuckle joint to connect two steel rods of equal diameter, Each rod is subjected to an axial tensile force of 50 KN. Design the {) rod ii) knuckle pin, considering all the possible failures, Take f= 45N/mm*, f,=40N/mm*, fy =60N/mm’. b) What are the functions of a lever? Define mechanical advantage and leverage. Answer: (WBSCTE 2016) 4) Given, tensile force, P = 50 KN = 50x10" N Allowable tensile stress, f= 45 N/mm? Allowable Shear stress, f, = 40 N/mm? Allowable Crushing stress, f, = 60N/mm? i) To design the diameter of the rod: Let d be the diameter of the rod, considering the failure of rod in tension, we can say, paddxs, or, 50x10? = 2d? x45 =1414,52 + 50x10" x4 on fae 5 =37.6mm=40mm or, Hence diameter of the rod is 40mm. i) Now, dimensions of the Knuckle Pin are selected empirically as follows: a) diameter of Pin, d, =d = 40mm b) diameter of Pin head, d, =1.5d or, d, =1.5x40= 60mm c) Thickness of Pin head, 1 = 0.5d or, 1=0.5x40=20mm Now, checking for the safety of the Pin for which dimensions are assumed. es i eet Failure of the Knuckle Pin is shear: As the Knuckle Pin is in double shear, pared, f or, 50x10" #21 (40) SONOS 20.Nimm? 2xnx(40) POLY-DMEDesian of Simole Machine Pais = MEA ‘The above stress is within permissible limit of shear stress. Therefore, the design of Pin is safe. b) A lever isa simple machine that allows us to gain a mechanical advantage. It consists of a rigid bar or beam that is allowed to rotate or Pivot about a fulcrum, along with an applied force and load. The tree types or classes of levers are available depending on where the fulerum and applied force is located, The function for a lever is that we can use it for a mechanical advantage in liftng heavy load by the application of small effor, moving things a greater distance or increasing the speed ofan object. Mechanical advantage is a measure ofthe force amplification achieved by using a tool, mechanical device or mechanical system. Ideally, the device preserves the input power and simply trades off forces against movement to obtain a desired amplification inthe cutput force. The model for this is the law of the lever. Mechanical advantage is calculated by dividing the output force by the input force. Leverage isthe other way to define mechanical advantage or to multiply force. Usually the term refers to the six classical simple machines: lever, wheel & axle. pulley, wedge, inclined plane and screw. > 13. Two rod ends of a pump shaft are joined by means of a cotter, spigot and socket ends. Design the joint for an axial load of 28 kN which alternatively changes from tensile to compressive. The allowable stresses for the material used are 50 N/mm? in tension, 35 N/mm” in shear and 90 N/mm in crushing. (DWBSCTE 2018) Answer: Given, Load on the cotter joint, 28KN = 28x10? W Allowable stress in tension, o, = 50 N/mm? Allowable stress in crushing (compression), ¢, = 90 N/mm? Allowable stress in shear, r =35 Némm? ‘There are three main parts of the joint: i) Spigot, i) Socket, (ii) CotterDESIGN OF MACHINE ELEMENTS DME.50 Specter] Socket collar Fig: Cotter joint ‘Notations used in design are as follows, P= Load on the joint or pull acting on rods, d=Diameter of the rod, di = outer diameter of socket, d2 = Diameter of spigot or inside diameter of socket, ds = Outside diameter of spigot collar, dy = diameter of socket collar, t: = Thickness of spigot collar, a = Distance from the end of the slot to end of spigot, ¢ = thickness of socket collar, b, ,1 = width, thickness and length of cotter. Fig: Spigot a) Considering the failure of rod tension (across section X-X): P=2a?xo, 4 28x10? =a? x50 tear 8x10? x4 = 713.375 d=26.7mm = 27mm (d= diameter of the rod) d, = diameter of the spigot and t= thickness of cotter = (empirical) POLY-DMEDesign of Simple Machine Parts DME.51 b) Considering the failure of spigot in tension across the cotter hole (section Y-¥): i.e, the weakest section. ‘Tearing strength of the spigot = [Sa 4, x ‘}: a zp =|2a3 -a, x1 \xo, e[fa | x 4, x10 =| 2a? a, x2], or, 28x10? = fr -1}x50 or, 28x10" Sx 2.142x50 28x10" x4 1045.75 = 32: ~ 4, = frags 7 1045-75 = 32:33mm ~ 35mm ©. Outside diameter of the spigot = inside dia. of the socket = 35 mm. 33 =8.75mm = 9mm thickness of the cotter, t= 4 ¢) Checking for induced crushing stress in the spigot or cotter: P=d,xIxo, or, 28x10" =35x9xo, 28x10" © 35x9 Since the induced crushing stress is less than permissible limit, the design is safe. or, = 88.88 N/mm? 4) Considering failure of spigot in shear: P=2xd,xaxt or, 28x10" =2x35xax35 pos a= distance from the end of the slot to 2" of spigot 28x10 PRA 11.42mm = 12mm 35035 e) Considering the failure of the cotter in shear: Since the cotter is in double shear: re, is P=2xbxtxr : 7) 28x10" =2xbx9x35 28x10? a re or, b= 28%10" - 44.44mm = 45mm 2x9%35 POLY-DMELig DESIGN OF MACHINE ELEMENTS DMES2 {Failure of socket in tension across the slot: Tearing seth of the socket ars the lt -[He-a)a-abep 3 olla 8} -apaho 28x10" or, a (0.78514? -962-94, +315] of, S60'=0.7857d? -9d, -647 or, d?~11.45d,-1536.2=0 g lst (as) +4x1%15362_ {14547922 ne 2d 2 = 45,33 =S0mm, (Considering postive value only} +. Outside diameter ofthe socket, d = 50 mm ¢) Failure of socket collar in crashing: Equatng the oad (P) with the rushing strength: : P=(d,-d,)xo,xt ‘TI 28x10" =(d, -33)«9%90 - hd o, or, 69,567 #70 mm. Ys -. Diameter ofthe socket collar, d, = 70mm ' 1) Failure ofthe socket end in shearing: ‘P= shearing strength of socket collar or, P=2x(d,-d,)kexr cx, Bxl0! =2(10-35)x35xc=2x35x35xe +E | 3 or, = 28x08 gomm= 1mm Lee! 35135 Thickness of socket collar, = 12mm {) Failure of spigot collar in crushing: Load = crashing strength of the spigot cola or, 28x10? =Hei-€)so, o, Budd =F (a -35)s90 ox, MAO yt 304895 0 POLI-DME_ Design of Simple Machine Parts DME.53 or, (1244.44 = ad? - 3848.95 or, ad? = 5093.39 1621.1 = 40.26mm = 45mm j) Failure of spigot collar in shearing: Load = Shearing strength of the collar ] or, 28x10? = ad, xt, xr or, 28x10? = 1x35x¢, x35 4 or, =7.27=8mm Spies «=. thickness of spigot collar, f, = 8 mm. | atk Shearing aea (A) = dy + > 14. It is required to design a knuckle joint for connecting two MS rod of equal diameter each rod subjected to an axial tensile force of 100 kN Take: tensile stress = 75 N/mm’, shear stress= 60 N/mm’, crushing stress = 150 N/mm*. [WBSCTE 2018} Answer: Given P = 100 KN = 100 10° N= 10°N o,=75N/mm?, ,=60N/mm*, 6, =1S0N/mm? a) Diameter of rods: Let d= diameter of the connecting rods. Considering the failure of rod in tension, P=2d xo, 4 or, 100%10 =a? «75 _ 100x104 mx75 d= 41.19mm- = 42mm" : Now the various dimensions of the knuckle joint are fixed empirically as follows: i) Diameter of the knuckle pin, d, =d = 42mm- ii) Quter diameter of eye, d, = 2d =2x 42 = 84mm. iii) Diameter of knuckle pin head and collar. iv) Diameter of pin head and collar, d, = 1.Sd =1.5x 42 = 63mm. v) Thickness of single eye on rod end, 1 = 125d =1,25% 42 = 52.5 = 53mm or, a = 1697.43 POLY-DMEni | DESIGN OF MACHINE ELEMENTS DME.54 vi) Thickness of fork, 1, = 0.7Sd =0.75x42=31.5mm = 32mm. vii) Thickness of Pin head, 1, = 0.5d =0.5x42= 21mm viii) Length of taper pin, ! = 1.75d =1.75x42=73.5 = 75mm. fe— 454 ——ple—— 4 Dethqwertainted . Single ee or rod end T ! f ao a tet a fsa anes Fee Fig: Knuckle joint b) Failure of knuckle pin in shear: Since the knuckle pin is in double shear, therefore Pa dnd xo, 10° = 2x5 (2)'xo, = 36.08N / mm? xax(42) The value is within limit, hence design is safe. ©) Failure of the forked end in tension: P=(d,—d,)x 21, x0, = (84—42)x 2x32, or, 10° =42x2x32xo, 10° =37.2N/ mm’, which is within the permissible limit. POLY-DMEDesign of Simple Machine Parts DME. d) Failure of the forked end in shear: P=(d,-d,)x24,x0, or, 10° =(84-42)x2x32xo, or, , = 37.2N mm? , which is within the permissible limit. ¢) Failure of the forked end in crushing: P=d,x2h,xo, or, 10° = 42x2x32xa, or, &, eu 37.2N/mm? , which is within the'limit 842x232 S {) Failure of the eye end in tension: P=(d,-d,)xtxo, or, (10° =(84-42)x53x0, 10° : or, == 44.92 mm 42x53 g) Failure of the eye-end in shear: Fig: Tensile failure of single eye-end d, 2 Resisting area under shear -(2- as0=(4 =d,) xt [due to double shear] P=(d,-d,)xtxo, 10° = (84 -42)x53xo, 10° ——— = 44.92N/ mm x53 )2.N | mm’ h) Failure of the eye-end in crushing: P=d.xtxo, Or, 10° =42x53xo, Or, o, =44.92N/mm* 10° © 42x53 From the above, we see that the induced stresses are less than the allowable stresses in all parameters. Therefore, the design of the joint is safe. > 15. Design a knuckle joint to with stand an axial load of 70Kn. The eye end, fork end, pin of the joint are made of mild steel having ultimate stress of 150 MPa in tension, 100 MPa in shear, and 180MPa in compression. Use factor of safety of 2 on ultimate stress. [WBSCTE 2019] Answer: Given P=70KN=70x10°N, F.0.S.=2 . 10 Allowable stress in tension, o; =/S2.Mr, 15 MP, =75 N/mm? POLY-DMEDESIGN OF MACHINE ELEMENTS: DME.56 Allowable stress in shear, o, 2 MP, =50 MP, = 50 N/mm? nk 180 yp, =90 MP, =90 N/mm? =i Allowable compressive stress, 0, Kowekle pin collar Knuckle pin Fig: Knuckle joint (a) Diameter of rods: Let d = diameter of the connecting rods Considering the failure of rod in tension, P=24'xo, 4 or, 10x10" = Fd? x75 fe 0 pp DOI 4 “953 axT75 or, d=34.77mm, let it be 36 mm (as per availability) Now the various dimensions of the knuckle joint are fixed empirically as follows: Diameter of the knuckle pin, d, =d = 36mm Outer diameter of eye, d, = 2d =2x36=72mm i) ii) POLY-DME_Dosian of Simple Machine Parts OME.57 iii) Diameter ofthe pin head and collar, d, =1.5d : 4, =1.Sd =1,5x36=54 mm iv) Thickness of single eye on rod end, 25d =1.25x36= 45mm ¥) Thickness of fork, 4, = 0.75d = 27mm vi) Thickness of pin head, ¢, = 0.5d = 0.5x36=18mm vii) Length of taper pin = 1.75d =1,75x36 = 63mm (b) Failure of knuckle pin in shear; Since the knuckle pin is in double shear, therefore Pardee, 3 10x10" =2x7x(36)' x, 10x10? x4 2x ax (36) The value is within limit, hence design is safe. =34.38 N/mm (©) Failure of forked end in tension: P=(d,-d,)x2t, xo ,=(72-36)x2x21x,) 0, =O 8 s6N femm? 36x2x27 The value is within permissible limit. (@) Failure of the forked end in shear: P=(d,-d,)x2t, xo, [double shear] 70x10" = (72-36)2x27x0, 70x10° -56x2%27 7 36N/mm , which is within limit. (@) Failure of the forked end in crushing: P=d,x2t,xo, or, 70x10? =36x2x27x0, i : =36 N/mm*, which is within limit. (O Failure of the eye-end in tension: P=(d,-d,)xtxo, POLY-DMEnk DESIGN OF MACHINE ELEMENTS OMES8 or, 10x10! =(72-36)x45xo, 1010" _ 43.2. N mm: whichis within limit. 65 (g) Failure ofthe eye-end in shear: Resisting area under shear 4, 5 }p2xt ue tn double sea] =| 1P=(d,-d)xtxoy “10x10? = (72-36) x45x0, ; 7, = 201 «43.2 N/mm? whichis within Limit 36x45 (h) Failure of the eye-end in crushing: P2d,xtxo, of, 70x10 =36x45x0, 70x10" 36x45 From the above, we have seen that the induced stresses are less than the allowable stresses in all parameters. Therefore, the design ofthe joint is safe 43.2. N/mm’ , which is within limit. or, 0, = 16. A wall bracket is attached by means of 9 identical bolts, as shown in Figure. Determine the diameter of the bolts if permissible shear stress for bolt material is 60 N/mm’, All dimensions are in mm. [WBSCTE 2020] POLY-DMEDME.59 Answer: on, permissible shear stress is 60 N/mm? First let us find the centre of gravity of bolted system Since all the bolts of same size and placed symmet bolt No. 5 i.e., at G. As all bolts equally share the direct shear load, hence direct shear load on each bolt, P_ 50x10” oh ° The direct shear load acts parallel to the direction of eccentric load P. Turning moment produced by the eccentric load P is, M=PC Qvhere C= eccentricity) 50 = 10? x 300=15~10° N-mm_ ‘The wrning moment tends to rotate the joint about C.G. i.e., “G* of the bolt system in a clockwise direction. Due to this turning moments secondary shear load on each bolt produced, _Here bolt 5" do not resist any turning moment but all other 8 bolts do resist. FP Pos Pos Fos Fos Fas Fy be secondary shear load on bolts 1, 2, 3, 4, 6, 7, 8 and 9 respectively. Distances of bolts 1, 2, 3, 4, 6, 7, 8 9 from C.G. ie, “G’ are Uslaslyslarlartyrterly Fespectively. From symmetry of figure, Vi00® +100" ly, C.G. of 9 bolt system lies at 555.5 N ae PSO 141-42 2 17677.72N Slax 141.42" + 41007 Now, & =F =F; 7677.72 Accordingly, F) PoLr-pMEni DESIGN OF MACHINE ELEMENTS DME.60 ReR=R=R= 151010019596 Sant 2 +4100" The resultant oad is Ra JF +P +R xP xeos8 “4a <.Ry = ANT6T.TE +55555° + 17671.72%5555.55%0.107 4122 am =203KN=R,=R,=R, and fo Z\ Ry = 12526" +5555.5° +12526x 5555.5x cos, uy oan 4 =90° 7 12526" + 5555.5? =13702.7N =13.7kN Itis seen that bolts 1,3, 7,9 are maximum loaded and to be designed on that load Let A be the bolt cross-sectional area, Permissible shear stress, oA 10 69 = 2030N 203: 10°N ad ; d= OSI 338.33? @ If 'd' be the diameter of the belt, or, Fa? 233833 4 © 17. Caloulate the diameter ofthe rods and the pin for a knuckle joint connecting two rods subjected to a pull of 120 kN. The rods and pin are made up of stecl Take f=45Nimm’, f, =40Nimm:, f= 60N/mm (in case of knuckle pin ignore bending failure). [WBSCTE 2022) Answer: Given, P= 120kN =120x10°N f=45Nimm?, f, =40 Nim’, f= 60 Nimm? POLY-DME