Hindusthan College of Engineering And Technology

Approved by AICTE, New Delhi, Accredited with ‘A’ Grade by NAAC

(An Autonomous Institution, Affiliated to Anna University, Chennai)
Coimbatore – 641 032
AUTONOMOUS UG/PG DEGREE INTERNAL EXAMINATIONS EVEN SEM 2018-19
BRANCH: B.E Mechatronics Engineering
COURSE CODE AND NAME: 16MT4204 MACHINE DESIGN

Name of Course Coordinator : Mr.Pradeep Johnson

Name of the course handling faculty members: : Dr.T.Venugopal

Test Unit/Portions for INTERNAL EXAM – I

Internal Test
Unit 1 & Unit 2 (First half)
1

PART A (2 Marks)
Marks COs
CO1
1. What is machine design? 2
(Remembering)
CO1
2. List some factors that influence machine design. 2
(Understanding)
CO1
3. Define Factor of safety. 2
(Understanding)
CO1
4. Define Endurance limit. 2
(Understanding)
CO1
5. State design process. 2
(Remembering)
CO1
6. List the different types of loads that can act on machine components. 2
(Understanding)
CO1
7. What are the types of variable stresses? 2
(Remembering)
CO1
8. Differentiate between repeated stress and reversed stress. 2
(Remembering)
CO1
9. Specify the types of fracture in materials. 2
(Remembering)
CO1
10. Define stress concentration and stress concentration factor. 2
(Understanding)
CO1
11. What are the three modes of failure of mechanical components? 2
(Remembering)
What are the factors to be considered in the selection of materials for a CO1
12. 2
machine element? (Remembering)
CO1
13. Name the five types of failure theories.
2 (Remembering)
CO1
14. Why normal stress theory is not suitable for ductile materials? 2
(Remembering)
A shaft of 70mm long is subjected to shear stress of 40 MPa and has an
CO1
15. angle of twist equal to 0.017 rad. Determine the diameter of the shaft. 2
(Applying)
Take G = 80 GPa.
CO1
16. Give some methods of reducing stress concentration. 2
(Remembering)
17. What is an S-N Curve? 2 CO1
1
 (Remembering)
CO1
18. State the principle stress and principle plane. 2
(Remembering)
CO1
19. What is preferred numbers? 2
(Remembering)
CO1
20. Write the methods used to improve fatigue strength. 2
(Remembering)
CO2
21. What is shaft? 2
(Remembering)
CO2
22. What is spindle? 2
(Remembering)
CO2
23. State the commonly used shaft materials 2
(Remembering)
CO2
24. Why maximum shear stress theory is used for shaft design? 2
(Remembering)
CO2
25. Why hollow shafts are used for large power transmission? 2
(Remembering)
CO2
26. Differentiate between the shaft and axle. 2
(Remembering)
Why hollow shaft has greater strength and stiffness than the solid shaft CO2
27. 2
of equal weight? (Remembering)
CO2
28. What are the various stresses induced in the shafts? 2
(Remembering)
CO2
29. Define the term critical speed 2
(Understanding)
CO2
30. List the factors considered to design a shaft. 2
(Understanding)
PART B(14 Marks)
Marks COs
A bolt is subjected to a tensile load of 25 kN and to a shear load of 10
kN. Suggest a suitable size of a bolt according to various theories of CO1
1. 14
failure. Take allowable yield stress is 300 N/mm2, Poisson’s ratio is (Applying)
0.25.
A shaft as shown in fig, is subjected to a bending load of 3kN, pure
torque of 1000 N-m and an axial force of 15kN. Calculate the stresses at
A and B.
A 3kN
CO1
2. 14
(Applying)
15kN

B
A cylindrical shaft made of steel having yield strength 760 N/mm 2, is
subjected to a static load consisting; bending moment of 15kN-m and
torsional moment of 25kN-m. if the required factor of safety is 2.5,
CO1
3. determine the diameter of the shaft using: 14
(Applying)
a. The maximum shear stress theory
b. The maximum strain energy theory
Assume E = 200 GPa and Poisson’s ratio = 0.25
4. A steel bar of 40mm diameter and 300 mm length is subjected to a 14 CO1
torque of 1 kN-m and two other loads as shown in fig. If the ultimate (Applying)
tensile strength and yield strength of the bar materials are 450 N/mm 2
2
 and 250 N/mm2 respectively. Determine factor of safety using;
1 kN-m
3kN
i) Maximum principal stress theory
ii) Maximum shear stress theory
iii) Maximum strain energy theory
10 kN

A steel shaft of 50 mm diameter is subjected to a bending moment of

2000 N-m and a torque T. If the yield point of the steel in tension is 200
CO1
5. MPa, find the maximum value of this torque without causing yielding of 14
(Applying)
the shaft according to (i) The maximum principal stress; (ii) The
maximum shear stress;
A circular bar of 500 mm length is supported freely at its two ends. It is
acted upon by a central concentrated cyclic load having a minimum
value of 20 kN and a maximum value of 50 kN. Determine the diameter
CO1
6. of bar by taking a factor of safety of 1.5, size effect of 0.85, surface finish 14
(Applying)
factor of 0.9. The material properties of bar are given by ultimate
strength of 650 MPa, yield strength of 500 MPa and endurance strength
of 350 MPa.
A shaft of diameter ‘d’ is subjected to a torque varying between 900 Nm
to 1800 Nm. Assuming a factor of safety 2 and a stress concentration
CO1
7. factor of 1.2, find the diameter of the shaft. Take ultimate stress = 650 14
(Applying)
N/mm2, yield stress = 480 N/mm 2, size factor B=0.85 and surface finish
factor C = 0.5
Determine the diameter of a circular rod made of ductile material with
an endurance limit of 25 MPa and tensile yield strength of 350 MPa. CO1
8. 14
The member is subjected to a varying axial load from-300 kN to 700 kN (Applying)
and has a stress concentration factor is 1.8. Take factor of safety as 2.
What are theories of failures and its importance in design? Explain any CO1
9. 14
two theories. (Understanding)
CO1
10. Explain various phases of design using a flow diagram. 14
(Remembering)
A cylindrical shaft of outer diameter double the inner diameter with 3m
length is subjected to a bending moment of 15000 Nm and torque of CO2
11. 14
25000 Nm and has an angle of twist to radians per meter length. Design (Applying)
the shaft with factor of safety of 2.
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 2.5 m apart.
CO2
12. Determine the size of the shaft, if the allowable shear stress is 42 MPa 14
(Applying)
and the maximum tensile or compressive stress is not to exceed 56
MPa.
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 200
N and is located at 300 mm from the centre of the bearing. The
diameter of the pulley is 200 mm and the maximum power transmitted CO2
13. 14
is 1 kW at 120 rpm. The angle of lap of the belt is 180° and coefficient of (Applying)
friction between the belt and the pulley is 0.3. The shock and fatigue
factors for bending and twisting are 1.5 and 2.0 respectively. The
allowable shear stress in the shaft may be taken as 35 MPa.
14. A belt pulley is keyed to the shaft midway between the supporting 14 CO2
bearings kept at 1000rpm apart. The shaft transmits 20KW power at (Applying)
400rpm. The pulley has 400mm diameter. The angle of wrap of belt on
3
 pulley is 180˚ and the belt tension acts vertically downwards. The ratio
of belt tension is 2.5. The shaft is made of steel having an ultimate
tensile strength and yield strength of 400N/mm 2 and 240 N/mm2
respectively. Kt and Kb are 1.5 and 1.25 respectively. The permissible
angle of twist is 0.25˚ per metre length. Design the shaft on the basis of
strength and rigidity. Take G = 80×103 N/mm2 and E = 200×103 N/mm2
A hollow transmission shaft, having inside diameter 0.6 times outside
diameter, is made of plain carbon steel 40C8 (S yt = 380 N/mm2). A belt
pulley of diameter 900 mm and weight 600 N is mounted on the shaft
and overhangs left hand bearing by 250mm. A pulley transmits power
CO2
15. to the machine shaft, which is below the pulley, through vertical belt. 14
(Applying)
The tension in tight and slack sides of the belt is 3 kN and 1 kN
respectively. The angle of wrap of the belt on the pulley is 180°. If
required factor of safety is 3, determine the outside and inside
diameters of the shaft.

PART C( 10 Marks)
CO1
1. Discuss in detail about the factors influencing machine design. 10
(Understanding)
What are the various mechanical properties of the metals which are
CO1
2. associated with the ability of the material to resist mechanical forces and 10
(Remembering)
load?
Discuss about the factors involved in selection of a proper material for CO1
3. 10
machine component. (Understanding)
A cylindrical shaft of made of steel Fe620, is subjected to a static loads
consisting of a bending moment 10kN-m and torsional moment 30kN-m. If the CO1
4. 10
required factor of safety is 2, determine the diameter of the shaft using (Applying)
maximum shear stress theory.
A steel rod of yield strength 350 N/mm2 and endurance limit of 265
N/mm2 is subjected to an axial load which varies from -300 kN minimum CO1
5. 10
to 700 kN maximum and has a stress concentration factor 1.8. Assume (Applying)
factor of safety 2. Calculate the diameter of the steel rod.
A 50 mm diameter shaft is made from carbon steel having ultimate tensile
strength of 600 MPa. It is subjected to a torque which fluctuates between CO1
6. 10
2000 N-m to -900 N-m. Using Soderberg method, calculate the factor of (Applying)
safety.
Explain in short the stress concentration factor and methods of relieving CO1
7. 10
stress concentrations. (Remembering)
A shaft is to transmit 50KW at 1200rpm. lt is also subjected to a bending
moment of 275 Nm. Allowable shear stress is 60N/mm 2 .The shaft is not to CO2
8. 10
twist more than 2° in a length of 2m. Assume G=80x10 3N/mm2. Design a (Applying)
shaft.
A hollow shaft of 0.5 m outside diameter and 0.3 m inside diameter is used
to drive a propeller of a marine vessel. The shaft is mounted on bearings 6
metre apart and it transmits 5600 kW at 150 rpm. The maximum axial CO2
9. 10
propeller thrust is 500 kN and the shaft weighs 70 kN. Determine (Applying)
i) The maximum shear stress developed in the shafts, and
ii) The angular twist between the bearings.
Determine the dimensions of the rectangular sunk key made up of mild
CO2
10. steel for an 80 mm diameter mild steel shaft to transmit a torque of 135 N- 10
(Applying)
m. Assume shear stress of 50 N/mm2 and crushing stress of 120 N/mm2.

Test Unit/Portions for INTERNAL EXAM – II

4
 Internal Test 2 Unit 2(Second half) & Unit 3

PART A (2 Marks)
Mark
Cos
s
CO2
1. What is a key? 2
(Remembering)
CO2
2. Write the various types of keys. 2
(Remembering)
CO2
3. What is the main use of woodruff keys? 2
(Remembering)
CO2
4. Identify the types of stresses developed in the key. 2
(Understanding)
CO2
5. What is the function of a coupling between two shafts? 2
(Remembering)
CO2
6. Under what circumstances flexible couplings are used? 2
(Understanding)
CO2
7. What are the purposes in machinery for which couplings are used? 2 (Remembering)

CO2
8. Name any two of the rigid coupling. 2
(Remembering)
CO2
9. Differentiate between keyways and splines. 2
(Understanding)
CO2
10. Brief on the effect of keyway on strength of a shaft. 2
(Understanding)
CO3
11. State law of gearing. 2
(Understanding)
CO3
12. Mention a few gear materials. 2
(Remembering)
CO3
13. What are the commonly used gear tooth profiles? 2
(Remembering)
14. Define Addendum and Dedundum 2 CO3
CO3
15. Why is a gear tooth subjected to dynamic loading? 2
(Remembering)
CO3
16. Compare the contact between mating teeth of spur and helical gears. 2 (Understanding)
CO3
17. What is helix angle? Give the standard angle used in helical gears. 2
(Remembering)
CO3
18. What is the advantage of helical gear over spur gear? 2
(Remembering)
CO3
19. State about herring bone gear. 2
(Remembering)
CO3
20. What is backlash in gears? 2
(Remembering)
CO3
21. When do we employ crossed helical gear? 2
(Remembering)
22. In what respects a helical gear is different than a spur gear? 2 CO3
(Understanding)
5
 CO3
23. What are the various forces acting on a bevel gear? 2
(Remembering)
CO3
24. When is bevel gear preferred? 2
(Remembering)
CO3
25. State the use of bevel gears. 2
(Remembering)
CO3
26. Specify the conditions based on which gear cutters are selected. 2
(Remembering)
CO3
27. What is mitre gear? 2
(Remembering)
Why is the crossed helical gear drive not used for power CO3
28. 2
transmission? (Remembering)
CO3
29. What is interference in gears? How to overcome it? 2
(Remembering)
How to improve the strength of gears, when subjected to surface CO3
30. 2
loads? (Remembering)
PART B(14 Marks)
Design a muff coupling to transmit 50 HP at 120 rpm. The shaft and
key are made of the same material having allowable shear stress of CO2
1. 14
30 N/mm2 and compressive stress of 80N/mm2. The flange is made (Applying)
of cast iron with allowable shear stress of 15 N/mm2
Design a rigid muff coupling. The power transmitted is 30 kW at
CO2
2. 360 rpm. Factor of safety is 6. Use C45 for the shaft. Assume other 14
(Applying)
data if required.
A protected type rigid flange coupling is used to transmit 25 kW
power at 500 rpm from an engine to a machine. Design a coupling
for an overload capacity of 25%. Assume following permissible
stresses for the components of a coupling.

CI (Flange) M.S (Shaft Plain carbon

and Key) steel (bolt)
CO2
3. Allowable tensile 14
20 60 60 (Applying)
stress, N/mm 2

Allowable shear stress,

12 35 28
N/mm2

Allowable compressive
60 60 60
stress, N/mm2

Design and draw a cast iron flange coupling for a shaft of 80mm
diameter transmitting 90kW at 250 rpm. The allowable shear stress CO2
4. 14
in the shaft is 40 MPa. The allowable shear stress in the coupling (Applying)
bolts is 30 MPa. and for the hub material is 14 MPa
Design a protected type rigid flange coupling to transmit 3.5 KW at
1440 rpm. The following are the materials used. For bolt C60 steel. CO2
5. 14
For shaft and key C40 steel, for flange CI grade 30. Use suitable (Applying)
factor of safety
6. Design a pair of spur-gears to transmit 10KW at a pinion speed of 14 CO3
1400 rpm. The transmission ratio is 3.6. Assume suitable materials (Applying)
6
 and stresses.
Two spur gears are to be used for a rock crusher drive and are to be
of minimum size. Gears are to be designed for the following
requirements: Power to be transmitted 18 kW, speed of pinion CO3
7. 14
1200 rpm, angular velocity ratio 3.5: 1, tooth profile 20° stub. (Applying)
Assume that gears are made of case hardened alloy steel. Design the
drive.
Design a cast iron spur gear drive for a crane hoist to transmit 3.75
KW at 1440 rpm. Maximum gear ratio in the gear box is 4. Each gear
CO3
8. is expected to work 2 hours per day for 110 years. Determine the 14
(Applying)
minimum centre distance, required face width and module of the
gear.
A pair of helical gears subjected to heavy shock loading is to
transmit 37.5 KW at 1750 rpm of the pinion. The speed reduction
ratio is 4.25 and the helix angle is 15°. The service is continuous and CO3
9. 14
the teeth are 20° full depths in the normal plane. Gears made up of (Applying)
alloy steel material. Design the gears. Calculate the major
dimensions and draw the arrangement
A helical gear with 30° helix angle has to transmit 35kW at 1500
rpm with a speed reduction ratio 2.5. If the pinion has 24 teeth,
CO3
10. determine the necessary module, pitch diameter and face width for 14
(Applying)
20° full depths the teeth. Assume 15Ni 2Cr 1 Mo 15 material for
both pinion and wheel
For intermittent duty of an elevator, two cylindrical gears have to
transmit 10 kW at a pinion speed of 1200 rpm. Design the gear pair
for the following specifications: Gear ratio 3.5, pressure angle 20°, CO3
11. 14
involute full depth, helix angle 15°. Gears are expected to work 6 (Applying)
hours a day for 10 years. Use alloy steel 40Ni2Cr1Mo28 for both
pinion and gear.
Design a herringbone gear for the data given below.
CO3
12. Power = 40 kW, Pinion speed =1800 rpm, gear ratio = 4, helix angle 14
(Applying)
= 25° and materials used = C45 steel.
Two straight bevel gears are used in a speed reducer with a
transmission ratio of 2. The wheel is supported on both sides and CO3
13. 14
the pinion is over hanging. The input is from a 20 kW electric motor (Applying)
running at 950 rpm. Design the bevel gears.
Design a straight bevel gear drive between two shafts at right angles
to each other. Speed of the pinion shaft is 250 rpm and gear wheel
shaft is 125 rpm. The pinion should have a minimum number of CO3
14. 14
teeth (but not less than 17) of involute profile. Choose suitable (Applying)
materials and design the gears for a power of 5KW of the pinion
shaft.
Design a pair of bevel gears for two shafts whose axes are at right
CO3
15. angles. The power transmitted is 25 kW. The speed of the pinion is 14
(Applying)
300 rpm and of the gear is 120 rpm.

PART C (10 Marks)

1. Design a muff coupling to connect two mild steel shafts to transmit 10 CO2
35kW at 1440 rpm. The CI sleeve connects the shafts through two mild (Applying)
steel sunk keys. The maximum torque transmitted is 25% greater than
the average torque.
Allowable shear stress for cast iron = 15N/mm 2 and mild steel =
65N/mm2, Allowable crushing stress for mild steel = 160 N/mm 2.
7
 Assume additional data, if necessary.
Design a protective type cast iron flange coupling for a steel shaft
transmitting 15kW power at 200 rpm. The maximum torque is 25%
more than the rated torque. Use the following data;
CO2
2. Allowable shear stress for shaft and key=40N/mm2 10
(Applying)
Allowable shear stress for bolts =30N/mm2
Allowable shear stress for C.I flanges =14N/mm2
Allowable crushing stress =2 x Allowable shear stress
Design a rigid muff coupling. The power transmitted is 30 kW at 360
CO2
3. rpm. Factor of safety is 6. Use C45 for the shaft. Assume other data if 10
(Applying)
required.
Explain the different causes of gear tooth failure and suggest possible CO3
4. 10
remedies to avoid such failures. (Remembering)
CO3
5. Describe the gear nomenclature with necessary sketch. 10
(Remembering)
A pair of gears to be designed for compact size. Power to be
transmitted 20 kW at 1450 rpm of pinion and gear ratio is 4. Tooth CO3
6. 10
profile 20° stub. Material for pinion is CS and for gear is CI. Design the (Applying)
gear drive.
A speed reducing unit using spur gear is to be designed. Power to be
transmitted is 60 hp and is continuous with moderate shock loads. The
CO3
7. speed of the shafts are 720 rpm and 144 rpm, respectively. The centre 10
(Applying)
distance is kept as small as possible. Select a suitable material and
design the gears. Give the details of the gears.
Design a pair of helical gears to transmit 10 kW at 1000 rpm of the
CO3
8. pinion. Reduction ratio of 5 is required. Give details of the drive in a 10
(Applying)
tabular form.
Design a helical gear drive to transmit the power of 20 hp. Speed ratio
CO3
9. 6, pinion speed 1200 rpm, helix angle is 25°. Select suitable materials 10
(Applying)
and design the gear.
Design a bevel gear drive to transmit 7kW at 1600rpm for the following
data; CO3
10. 10
Gear ratio = 3, material for pinion and gear = C45 steel, life = 10,000 (Applying)
hours.

Test Unit/Portions for MID SEMESTER EXAM

Mid-Sem Test Unit 1, 2, 3 & Unit 4 (First half)

PART A (2 Marks)
Marks Cos
CO4
1. Write the features of a chain drive. 2
(Remembering)
CO4
2. List the five parts of roller chain? 2
(Remembering)
CO4
3. What is a silent chain? In what situations, silent chains are preferred? 2
(Remembering)
CO4
4. How is a driving chain designated? 2
(Remembering)
CO4
5. Define galling in roller chains. 2
(Remembering)
6. Mention the applications of chain drives. 2 CO4
8
 (Remembering)
CO4
7. What is meant by ‘chordal action of chain’? 2
(Remembering)
Which are the factors will affect the working conditions of a chain CO4
8. 2
drive? (Remembering)
CO4
9. What is slack adjuster? 2
(Remembering)
CO4
10. Under what conditions, chain drives are preferred over belt drives? 2 (Understanding)

PART B( 14 Marks)
Marks COs
Briefly explain the method of selecting a suitable chain for CO4
1. 14
transmitting the given load. (Understanding)
Design a chain drive to actuate a compressor from a 15 kW electric
motor running at 1000 rpm. The compressor speed is 350 rpm. The
CO4
2. minimum centre distance is 500 mm. The compressor operates 16 14
(Applying)
hours per day. The chain tension adjusted by shifting the motor on
slides.
A 10 kW, 1440 rpm motor drives a line shaft at 300 rpm by a chain
drive. The centre to centre distance of the shaft is to be approximately
CO4
3. 0.5 m. The motor shaft diameter is 40 mm. The starting torque of the 14
(Applying)
motor is 2.5 times the running torque. The load applied is with
moderate shock. Select a suitable roller chain drive.
A bucket elevator is to be driven by a geared motor and a roller chain
drive with the information given below.
Motor output = 3 kW; speed of the motor = 100 rpm; elevator drive
CO4
4. shaft speed = 42 rpm; load = even; distance between centres of 14
(Applying)
sprocket approximately = 1.2 m; period of operation = 16 hours/day;
Geared motor is mounted on an auxiliary bed for centre distance
adjustments. Design the chain drive
A roller chain drive is used between a driver running at 1000 rpm and
a drives shaft running approximately at 320 rpm. The power
transmitted is 10 kW. The drive is to be used for 2 shifts/day with 8 CO4
5. 14
hours per shift. The centre distance is approximately 700 mm and the (Applying)
chain tension can be adjusted by moving the motor in the rails. Design
the drive.

PART C(10 Marks)

CO4
1. Discuss the classification of chains and their essential components. 10
(Remembering)
Design a chain to transmit 7.5 kW at 960 rpm of the sprocket pinion. A
speed reduction of 2.5 to 1 is desired. The drive is horizontal and the CO4
2. 10
motor is mounted on an adjustable base. A service of 12 hours per day is (Applying)
envisaged.
Select a suitable roller chain for the specified details given below:
Power to be transmitted = 30 kW at a small sprocket speed of 1000 rpm. CO4
3. 10
The driven shaft runs at 500 rpm. The chain will be subjected to a (Applying)
intermittent overloads of 100%. Take Ks = 2.0.
A 15 kW squirrel cage motor, 1250 rpm is driving a centrifugal pump at
CO4
4. 550 rpm. The centrifugal pump is located at 700 mm from the motor. 10
(Applying)
Design a chain drive.
9
 Specify the design procedure of chain sprocket. Also mention the causes CO4
5. 10
of chain failure. (Remembering)

Test Unit/Portions for INTERNAL EXAM – III

Internal Test 3 Unit 4 (Second half) & Unit 5

PART A (2 Marks)
CO4
1. Enumerate major classification of braking. 2 (Understanding)

What is the advantage of band brake over block brakes? CO4

2. 2
(Remembering)
CO4
3. Give the expression for braking torque of a differential band brake. 2
(Remembering)
CO4
4. List the desirable properties of friction materials used for brake shoes. 2 (Remembering)
(Remembering)
Why should the temperature rise be kept within the permissible range CO4
5. 2
in brakes? (Remembering)
CO4
6. What is meant by self-energizing brakes? 2
(Remembering)
CO4
7. Differentiate between brake and clutch. 2 (Understanding)

CO4
8. What factors influence capacity of a brake? 2
(Remembering)
Automobile braking is not effective when moving in reverse direction, CO4
9. 2
justify. (Understanding)
CO4
10. State the advantages of disc brake over drum brakes. 2
(Remembering)
CO5
11. Define Bearing 2
(Remembering)
CO5
12. Classify the bearings 2 (Understanding)

CO5
13. List any four types of bearing materials. 2
(Remembering)
CO5
14. What are the required properties of bearing materials? 2
(Remembering)
CO5
15. State the components of rolling contact bearings. 2
(Remembering)
CO5
16. List any four advantages of rolling contact over sliding contact bearings. 2
(Remembering)
CO5
17. Give an example for antifriction bearing. 2
(Remembering)
CO5
18. What is lubricant? State its functions. 2
(Remembering)
What are the types of journal bearings depending upon the nature of CO5
19. 2
contact? (Remembering)
CO5
20. What is known as self – acting bearing? 2
(Remembering)
10
 CO5
21. What is a spring? 2
(Remembering)
CO5
22. State any two functions of springs. 2
(Remembering)
CO5
23. What are the various types of springs? 2
(Remembering)
CO5
24. Define spring index and spring rate 2
(Remembering)
CO5
25. What is buckling of springs? 2
(Remembering)
CO5
26. What is surge in springs? 2
(Remembering)
CO5
27. State the purpose of leaf springs. 2
(Understanding)
CO5
28. Write the advantage of leaf spring over helical spring. 2
(Remembering)
CO5
29. What is meant by nip in leaf springs? 2
(Remembering)
CO5
30. List the various applications of springs. 2
(Remembering)

PART B(14 Marks)

Mar COs
ks
The block brake as shown in figure, provides a braking torque of 360 N-
m. The diameter of the brake drum is 300 mm. The coefficient of friction
is 0.3. Find the force (P) to be applied at the end of the lever for the
clockwise and counter clockwise rotation of the brake drum and the
location of fulcrum to make the brake self locking for the clockwise
rotation of the brake drum.
CO4
1. 14
(Applying)

In a single block brake, the diameter of the drum is 250 mm and the angle
of contact is 90°. If the operating force of 700 N is applied at the end of
lever which is at 250 mm from the centre of the brake block. The CO4
2. 14
coefficient of friction between the drum and the lining is 0.35. determine (Applying)
the torque that may be transmitted. Fulcrum is at 200 mm from the
centre of brake block with an offset 50 mm from the surface of contact.
3. Calculate the average bearing pressure and the initial and average 14 CO4
braking powers for the block brake as shown in figure. The diameter of (Applying)
the drum is 500 mm and it rotates at 250 rpm. Coefficient of friction is
0.25 and drum width is 80 mm.

11
 A band brake is to be designed for a winch to lift load of 20 kN through a
15 m height by a rope wire wound on a barrel of 450 mm diameter. The
hoisting cycle is 3 minutes, out of which the actual braking time is 60 CO4
4. 14
seconds. The angle of contact between the band and the brake drum is (Applying)
20°. The brake drum may be keyed to the same shaft. Give the complete
design.
Design a differential band brake for a winch lifting a load of 20 kN
through a steel wire rope wound a barrel of 600 mm diameter. The brake
CO4
5. drum , keyed to a barrel shaft is of 800 mm diameter and the angle of lap 14
(Applying)
of the band over the drum is about 240°. Operating arms of the brake are
50 mm and 250 mm. the length of operating lever is 1.6 m.
Enumerate the types, properties and applications of bearing lubricants. CO5
6. 14
Also explain the basic modes of lubrication. (Understanding)
Select a suitable deep groove ball bearing for supporting a radial load of
CO5
7. 10 kN and an axial load of 3 kN for a life of 4000 hours at 800 rpm. Select 14
(Applying)
from series 63. Calculate the expected life of the selected bearing.
A ball bearing subjected to a radial load of 5 kN is expected to have a life
of 8000 hours at 1450 rpm with a reliability of 99%. Calculate the CO5
8. 14
dynamic load capacity of the bearing so that it can be selected from the (Applying)
manufacturer’s catalogue based on a reliability of 90%.
The load exerted on a journal bearing turbine shaft of 300 mm diameter
running at 1800 rpm is 150 KN. Determine the following. (i) Length of
the bearing if the allowable bearing pressure is 1.6 N/mm 2 and (ii) CO5
9. 14
Amount of heat to be removed by the lubricant per minute if the bearing (Applying)
temperature is 60°C and viscosity of the oil at 60°C is 0.02 N-s/m 2 and
the bearing clearance is 0.25 mm.
Design a journal bearing for a centrifugal pump from the following data:
Load on the journal = 20,000N; type of oil is SAE 10, for which the
absolute viscosity at 55°C = 0.017 kg/m-s; Ambient temperature of oil =
CO5
10. 15.5°C; Maximum bearing pressure for the pump = 1.5 N/mm 2. Calculate 14
(Applying)
also mass of lubricating oil required for artificial cooling, if rise of
temperature of oil be limited to 10°C. Heat dissipation coefficient = 1232
W/m2/°C.
It is required to design a helical compression spring with plain ends, for
carrying a maximum static force of 1200N. The allowable shear stress
and modulus of rigidity for spring material are 400 N/mm 2 and 85
N/mm2 respectively. The spring rate is 48 N/mm. if spring index is 5, CO5
11. 14
determine: (Applying)
a. Wire diameter; b. total number of coils; c. free length; and d.
pitch.
Draw a neat sketch of spring and give necessary dimensions.

12
 Design a helical compression spring for a Ramsbottom safety valve
shown in figure, with following data:
a. Operating pressure = 1 N/mm2
b. Maximum lift = 6 mm at 10% pressure
rise over operating pressure
CO5
12. c. Diameter of valve = 100 mm 14
(Applying)
d. Permissible shear strength for spring
material = 375 N/mm2
e. Modulus of rigidity for spring
material = 83×103 N/mm2
f. Spring index = 6
A truck has 12 numbers of leaves, two of which are full length leaves. The
spring supports are 1.05 m apart and the central band is 85 mm wide.
The central load is to be 5.4 kN with a permissible stress of 280 MPa. CO5
13. 14
Determine the thickness and width of the steel spring leaves. The ratio of (Applying)
the total depth to the width of the spring is 3. Also determine the
deflection of the spring.
A locomotive spring has overall length of 1.1 m and sustains a load of
75kN at its centre. The spring has 3 extra full length leaves and 15
graduated leaves with a central band 100mm wide. All leaves are to be
stressed to 420 N/mm2, when fully loaded. The ratio of total spring depth
CO5
14. to width is to be approximately 2. If the modulus of elasticity is 2.1×10 5 14
(Applying)
N/mm2, determine i) the width and thickness of leaves, ii) The initial
space that should be provided between the full length and graduated
leaves before the band load is applied and iii) the load exerted on the
band after the spring is assembled.
A safety valve of 60 mm diameter is to blow off at a pressure of 1.2
N/mm2. It is held on its seat by a close coiled helical spring. The
maximum lift of the valve is 10 mm. Design a suitable compression spring
of index 5 and providing an initial compression of 35 mm. The maximum CO5
15. 14
shear stress in the material of the wire is limited to 500 MPa. The (Applying)
modulus of rigidity for the spring material is 80 kN/mm 2. Calculate: 1.
Diameter of the spring wire, 2. Mean coil diameter, 3. Number of active
turns and 4. Pitch of the coil.

PART C(10 Marks)

1. Calculate the average bearing pressure and the initial and average braking 10 CO4
powers for the block shoe shown in figure. The diameter of the drum is (Applying)
400 mm and it rotates at 200 rpm. Coefficient of friction is 0.2 and drum
width is 75 mm.

Why in automobiles, braking action when travelling in reverse is not as CO4

2. 10
effective as when moving forward? Discuss. (Applying)
3. Figure shows the arrangement of two brake shoes which act on the 10 CO4
internal surface of a cylindrical brake drum. The braking force F1 and F2 (Applying)
are applied as shown and each shoe pivots on its fulcrum O1 and O2. The
width of the brake lining is 35 mm. The intensity of pressure at any point
A is Sin ɵ N/mm2, where ɵ is measured as shown from either pivot. The
13
 coefficient of friction is. Determine the braking torque and the magnitude
of the forces F1 and F2.

Enumerate the detail steps involved in the selection of bearings from the CO5
4. 10
manufacturer’s catalogue. (Applying)
A deep grove ball bearing having bore diameter of 60 mm and rotating at
1440 rpm is subjected to a radial force of 2500 N and an axial force of
1200 N. The radial and thrust factors are 0.56 and 2.0 respectively. The CO5
5. 10
load factor is 1.2. If the expected rating life is 25,000 hours, calculate the (Applying)
required basic dynamic capacity of the bearing and select the bearing
from manufacturer’s catalogue.
The load on the journal bearing is 150 kN due to turbine shaft of 300 mm
diameter running at 1800 rpm. Determine the following:
1. Length of bearing if the allowable bearing pressure is 1.6 N/mm 2,
CO5
6. and 10
(Applying)
2. Amount of heat to be removed by the lubricant per minute if the
bearing temperature is 60°C and the viscosity of the oil at 60°C is
0.02 kg/m-s and the bearing clearance is 0.25 mm.
Design a journal bearing for 12 MW, 1000 rpm steam turbine, which is
supported by two bearings. Take the atmospheric temperature as 16°C CO5
7. 10
and operating temperature of oil as 60°C. Assume viscosity of oil as (Applying)
23Ns/m2.
Design a coil spring to carry a load of 500N with an allowable deflection of
CO5
8. 25mm. The spring index may be taken as 6. Suitable material may be 10
(Applying)
assumed with a factor of safety 3.
Design a leaf spring for the following specifications: Total load = 140 kN;
number of springs supporting the load = 4; maximum number of leaves = CO5
9. 10
10; permissible deflection = 80 mm. take Young’s modulus, E = 200 (Applying)
kN/mm2 and allowable stress in spring material as 600 MPa.
10. In automobiles, coil spring is better than leaf spring to provide cushioning 10 CO5
effect. List down the reasons. (Understand
ing)

Note: Kindly provide maximum number of questions for each examination.

SIGNATURES:

Name of the course coordinator: Mr.Pradeep Johnson

Name of the course handling faculty: Dr.T.Venugopal

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HOD DEAN ADVISOR/COE

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