MD - IES CONVENTIONAL 1995-2015

1995 PAPER-2
26. A motor drives a main shaft by means of
a flat belt. The diameters of the pulleys on
the motor shaft and the main shaft , are
450 mm and 750 mm respectively.
Another pulley of diameter 500 mm
drives a counter shaft having a pulley of
diameter 700mm. The pulley of diameter
500mm is mounted on the main shaft. If 1997 Paper -2
the slip on each drive is 3 percent, 29. A square threaded bolt of mean diameter
calculate the speed of counter shaft if 24 mm and pitch 5 mm is tightened by
motor runs at 1400rpm. (20) screwing a nut, whose mean diameter of
bearing surface is 50 mm. If the
1996 – Paper - 2 coefficient of friction for nut and bolt is
27. An automotive single-plate clutch consists 0.1 and that for nut and bearing surface is
of a pair of contacting surfaces. The inner 0.15, find the force required at the end of
and outer diameters of friction plate are a spanner 0.5 m long, when the load on
120 mm and 250 mm respectively. The the bolt is 12 kN. (15)
coefficient of friction is 0.25 and the total
axial force is 15 kN. Calculate the power 30. A V-belt of 6.0 cm² cross-section has a
transmitting capacity of the clutch plate of groove angle of 40° and an angle of lap of
500 rpm using (i) uniform wear theory 150°  = 0.1. The mass of belt per meter
and (ii) uniform pressure theory. (24) run is 1.2 kg. The maximum. allowable
stress in the belt is 850 N/cm2 Calculate
28. A transmission shaft supporting two the horse power that can be transmitted at
pulleys A and B are mounted between two a belt speed of 30 m/s. (20)
bearing and as shown in Figure.
31. A mild steel shaft has to transmit 100 hp
Power is transmitted from pulley A to B.
at 200 rpm.
The shaft is made of plain carbon steel
Design a cast iron flange coupling for the
having ultimate tensile strength = 600
shaft. The allowable stresses are as
N/mm² and yield strength = 380 N/mm².
follows :
Determine the shaft diameter on the basis
Shear stress for shaft and key =40 N/mm²
of torsional rigidity, if the permissible
Shear stress for bolts = 28 N/mm²
angel of twist between two pulleys is 0.5°
Shear stress for C.I. coupling = 20 N/mm²
and the shear modulus of the material is
Take bearing stress as twice the shear
. The permissible shear stress stress value and number of bolts for the
may be taken as 30% of the yield strength coupling as 6.
of 18% of the ultimate tensile strength, Sketch the Coupling showing various
whichever is minimum, Check for its- dimensions. (30)
safety. (24)

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 MD - IES CONVENTIONAL 1995-2015

1998 Paper - 2 ropes = 10. Mass of the rope = 55C2 kg/m.

32. The semi-circle angle of a cone clutch is Length and working tension of rope is
12.5° and the contact surfaces have a limited to 125 C2 kN, where C is the
mean diameter of 80 mm. The coefficient circumference of rope in meter. Find
of friction is 0.32. (i) the initial tension and
(i) What is the minimum torque (ii) diameter of each rope. (20)
required to produce slipping of the
clutch for an axial force of 200 N? 2001 Paper-2
If the clutch is used to connect an 35. Design a set of stepped pulleys to drive a
electric motor with a stationary machine from a counter-shaft that runs at
flywheel, 220 rpm. The centre distance between the
(ii) what is the time needed to attain twos sets of pulleys is 2 m. The diameter
the full speed and of the smallest step on the countershaft is
(iii) the energy lost during slipping? 160 mm. The machine is to run at 80, 100
Motor speed is 900 rpm and the moment and 130 rpm and should be able to rotate
of inertia of the flywheel is 0.4 kg m2. in either directions. Find the length of the
(iv) What are the considerations in the belt required for both cases. (15)
selection of plate clutches and cone
clutches? (20) 2002 PAPER - II
36. A transmission shaft, rotating at 500
1999 PAPER - II r.p.m., drives a milling machine which
33. A 100 mm dia shaft operating at 2000 requires 3.75 kW at 750 r.p.m. A 300 mm
rev/min is supported by means of a 150 diameter cast iron pulley is mounted on
mm long full journal bearing which is the transmission shaft. A preliminary
subjected to a radial load of 43 kN. design proposes using a belt 4.75 mm
Assume (N /P) = 30 x 10-6. Determine thick, which has a density of 970 kg /m².
(i) the coefficient of friction using The allowable stress is 2 MPa. Two
McKee equation pulley rotate in opposite directions and
which is given by the centre distance of the shafts is 750
f = 0.326 (N/P)D/C + K mm. The coefficient of friction is 0.3 for
take D/C = 1000, K = 0.002. both the pulleys. Determine the width of
(ii) bearing pressure in MN/m2. the belt. (10)
(iii) heat generated. (10)
37. A 5 cm diameter solid shaft is welded to a
2000 Paper - 2 flat plate by 1 cm fillet weld. What will
34. A rope pulley is designed to transmit 30 be the maximum torque that the welded
kW. Diameter of pulley = 360 mm. Speed joint can sustain if the permissible shear
= 120 rpm. Angle of groove = 45°. Angle stress in the weld material is not to
of lap on smaller pulley = 170°. exceed 8 kN/cm2 ?
Coefficient of friction = 0.27. Number of Deduce the expression for the shear stress
at the throat from the basic theory. (10)
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 MD - IES CONVENTIONAL 1995-2015

2005 PAPER - II
2003 Paper – 2 44. A full journal bearing operating under a
39. Name the processes by which external steady load has the following
screw thread can be produced (both specifications : (20)
manually using tools and in machines). (l) Journal diameter: 60 mm
(10) (2) Bearing length : 60 mm
(3) Radial load on bearing: 2·8 kN
2004 Paper - 2 (4) Journal speed: 1020 rpm
40. An antifriction bearing used in a gear box (5) Radial clearance: 0·05 mm
has a specification 6108. What do the (6) Viscosity of oil: 80×10–9 N-s/mm²
numbers 6, 1 and 08 signify? (12) (7) Density of oil : 860 kg/m³
(8) Specific heat of oil: 1.76 kJ/kg-°C
41. Mention three different methods used to Using Raymonds & Boyd table given at
prevent an antifriction bearing from the end of the problem, determine
sliding axially in a shaft at the inner race (i) Sommerfeld Number
and in a bore at the outer race. (18) (ii) Power loss in friction
42. Which one of the three bearings listed (iii) Temperature rise if heat generated
below will you choose to take a heavy is entirely carried by oil
axial load on the bearing (i) self (iv) Minimum film thickness, and its
aligning ball bearing (ii) deep groove location
ball bearing (iii) Thrust bearing. Give Table - Giving Raymond’s & Boyd data
reasons for your selection. (10) for journal bearing for L/D = 1

43. A hot rolled steel shaft is subjected to a

torsional load that varies from 300 kNmm
clockwise to 100 kNmm anticlockwise as
an applied bending moment at a critical
section varies from +400 kNmm to -200
kNmm. The shaft is of uniform corss
section and no key-way is present at the
critical section. Determine the required 45. A car has a three cylinder engine which
shaft diameter by taking factor of safety produces maximum torque of200 N-m at
1.5. For the material, take ultimate tensile 2000 rpm. The power is transmitted by a
stress as 560 MPa, stress at yield point single plate friction clutch of230 mm
420 MPa design stress is 280 MPa. Also outside diameter. Design dimensions of
take the modification factor as 0.62, size friction surfaces. Further when the car is
correction factor as 0.85, the load factor engaged at a speed of 60 km/hr, calculate
for bending as 1 and the load factor for the clutch slip period (time) during
torsion as 0.58. (40) engagement. (20)
Additional data as under :

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 MD - IES CONVENTIONAL 1995-2015

(i) Engine speed at beginning of

clutch engagement : 2000 rpm 47. Draw a neat sketch for the Flange
(ii) Engine torque at engagement: 100 coupling with the designed dimensions.
N-m (20)
(iii) Mass of car (loaded) : 1500 kg
(iv) Wheel diameter: 710 mm 48. A centrifugal clutch with four shoes is
(v) Coefficient of friction: 0·3 used to transmit 15 kW to 720 r.p.m. The
(vi) Permissible pressure for friction speed at which engagement begins is 80%
material: 0·25 N /mm² of full speed. The inside diameter of the
(vii) Mass moment of inertia of engine drum is 325 mm and outside diameter of
rotating parts, flywheel and the drum is 350 mm. The radial distance
driving side of clutch 1·5 kg-m² of C.G. of each shoe from the axis of
(viii) Gear reduction at differential: 4·12 shaft is 120 mm. The radial clearance
(ix) Torque available at the rear between the shoe and the rim is 10 mm.
wheels: 105 N-m Uniform wear The pressure exerted on the shoe during
theory may be used for the clutch engagement is 0·1 MPa. The coefficient
plate design. of friction between shoe lining and the
drum is taken as 0·25.
2006 PAPER - II Determine:
46. Design and draw a cast iron flange (i) Mass of each shoe.
coupling for a mild steel shaft (ii) Size of the shoe if the angle
transmitting 80 kW at 220 r.p.m. with the subtended by shoe at centre is 60°.
following specifications: Also design the helical spring used
Allowable shear stress in the shaft = 40 in the shoes taking the safe shear
MPa Permissible angle of twist < l° in stress of spring material as 600
a length of 20 diameters. MPa and modulus of rigidity of
Allowable shear stress in the coupling the material as 80 kN/mm2. Use
bolts = 30 MPa. Rigidity modulus of shaft the spring index of 6. (20)
material = 85 GPa
Allowable shear stress for hub material = 2007 Paper - 2
15 MPa 49. Design a flat belt drive system for the
You may adopt, following specifications :
Width of key = 25 mm Power to be transmitted = 100 kW
Thickness of key = 14 mm Pulley diameters = 0·8 m and 1 m,
You may also consider that the shaft and respectively
key are made of the same material. Centre distance between the pulleys = 3m
Four number of bolts are to be used in the Belt speed = 20 m/s
coupling. Find out the diameter of the Coefficient of friction between the belt
shaft required and the main dimensions of and pulleys = 0·3
the Flanges and the Key. Adopt suitable Slip = 1.2% at each pulley
dimensions. Friction loss at each shaft = 5%
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 MD - IES CONVENTIONAL 1995-2015

Overload capacity = 20%

Density of leather belt material = 1000
kg/m³
Safe stress for the belt = 2·5 MPa
Thickness of the belt = 12 to 16 mm
Take into account the effect of centrifugal
tension.
Find the width and the length of the belt.
Draw a schematic diagram of the belt
drive. (20)
2009 Paper - II
50. A shaft ABCD is supported at one end A 52. The screw of a car lift has 150 mm dia.
and at point C. The other end D consists with square threads of 50 mm pitch and
of a pulley which has belt tensions in the lead of 100 mm. Assume 1000 N is
vertical direction. The distance AD is required for lifting of the car and thread
1200 mm. AC distance is 800 mm. A spur friction coefficient is 0.20.
gear having pressure angle 20° is mounted (i) Compute the torques required to
at point B which is at a distance 400 mm rotate the screw to raise the car
from A. The diameter of pulley is 450 and lower the car. Also compute
mm and that of the gear is 300 mm. The the overall efficiency of the screw.
gear is supplied power equal to 20 kW at (ii) What is the flaw in the above
500 rpm by another gear at the top of it. design? (15)
The tension on the tight side is 3 times the
tension on slack side in the belt. The 53. Most of the times the rotating disc-shafts
combined shock and fatigue factors for have keys; under such conditions it cannot
bending moment and torsional moment be assumed that the shaft has a uniform
may be taken as 1·5. The tensile strength cross-section. For such a disc-shaft
of the material of the shaft and key is 700 system how will you determine the limits
MPa. Design the shaft and key for the of speed for instability ? (5)
pulley assuming factor of safety equal to
5. Assume allowance for the key way for 2010 PAPER – II
stress as 0.75. (20) 54. Two railway coaches are coupled with the
help of two tie rods of a turn buckle with
2008 PAPER - II right and left handed threads having
51. Determine the size of the weld required single-start square threads. Pitch and
for static loading in the eccentrically mean diameter of the threads are 8 mm
loaded weld as show in the figure below. and 30 mm respectively. How much
Allowable stress for the weld may be energy will be spent in bringing two
taken as 75 N /mm 2. O the CG of the coaches closer through a distance of 320
weld area. (20) mm against a steady load of 5.0 kN. Use
coefficient of friction in screw thread and

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 MD - IES CONVENTIONAL 1995-2015

coupler nut as 0.12. Determine shear 2012 Paper - 2

stress on the tie rod due to above torque. 59. The following particulars refer to a screw
(10) jack shown in Figure below :
Vertical load on the screw W=20000 N
55. A flat belt drive is required to transmit 10 Force applied at the lever end whose
kW from a motor running at 1000 rpm. length l = 80cm
The belt is 15 mm thick and has a mass Mean radius of the screw r=2.5cm
density of 0.001 gm/mm3. Permissible Pitch of the screw p=1cm
tensile stress for the belt material is 2.5 Mean radius of contact surface between
N/mm2. Diameter of the driving pulley is swivel & head rm=4cm
250 mm, whereas the speed of the driven Coefficient of friction between
pulley is 367 rpm. Driving and driven screw thread and bearing ’ = 0.15
shafts are 1.25 m apart. The coefficient of Coefficient of friction between the swivel
friction between belt and pulley may be head and bearing  = 0.1
taken as 0.25. Determine the width of the Determine :
belt for safe working. () (i) the force on the lever end required
while raising and lowering the
2011 Paper - 2 load.
56. A hollow shaft whose ratio of internal (ii) the efficiency of the screw jack in
diameter to external diameter (k) is 0.5, both cases. (12)
transmits 1.5 kW at 1400 rpm. At a
certain section it is also subjected to a
bending moment of 5 N.m. The shaft is to
be made from chrome-vanadium steel
having allowable shearing stress of 200
MPa. Design the shaft using the ASME
code formula for transmission shafting as
given below :
Do (outer diameter) =

Combined shock and fatigue factor for

bending moment (Cm) is 1.5. 60. An open belt system is transmitting 10
Combined shock and fatigue factor for kW power. Driving pulley is of diameter
torque (Ct) = 1.0. Determine the internal 200 mm and driven pulley is of diameter
and outer diameter of the shaft. (15) 480 mm. Centre distance between the
pulleys is 2 m. Maximum stress in belt is
57. What are common modes of failure of not to exceed 2.2 MPa. Thickness of the
rolling element bearings? (5) belt is 8 mm. Determine breadth and
length of the belt. Given density of belt

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 MD - IES CONVENTIONAL 1995-2015

material = 950 kg/m3 Coefficient of coupling and verify all the major
friction between belt and pulley = 0.3. dimensions for strength. (20)
Driving pulley is rotating at 1000 rpm.
Neglect bending stress in belt. (20) 64. A full journal bearing has a journal
diameter D of 25 mm, with a unilateral
61. What are different types of threads used tolerance of - 0.038 mm. The bushing
for power transmission ? Make a simple bore has a diameter B of 25.038 mm and a
sketch of each. Give special features of unilateral tolerance of 0.075 mm. The l/D
each thread and their applications. (10) ratio is unity. The load is 1.1 kN and the
journal runs at 18.33 r.p.s. The average
62. Fatigue life of a 6 x 37 wire rope of viscosity is 55.2 mPa-s.
nominal diameter of 12 mm is to be Minimum film thickness variable is 0.58
achieved to be 0.2 billion bends. Tensile and coefficient of friction variable is 4.0.
stress designation of wire rope is 1960 Find
MPa. How much load can be lifted (a) Sommerfeld number
through a sheave of diameter 400 mm, (b) minimum film thickness
through the arrangement shown in figure. (c) frictional torque. (10)
Take ratio of bearing pressure between
rope and sheave to ultimate strength of
rope = 0.0024. (10) 2014 Paper - 2
67. A drive shaft of 40 mm diameter
transmitting 25 kW at 300 rpm is
connected to a gear by a flat key of width
22 mm and thickness 14 mm. It is made
of steel having 300 MPa yield stress.
Determine the length of the key to
withstand shear. use a factor of safety 2.
(4)

2013 Paper – 2 68. A plate clutch has a single surface with an

63. A 100 mm steel drive shaft transmitting outside diameter of 250 mm and inside
150 kW at 300 r.p.m. has to be connected diameter of 100 mm with a coefficient of
to a machine having same diameter shaft friction 0.4. Find the required axial force
with a cast iron (CI) unprotected flange to develop a maximum pressure of 0.65
coupling. The permissible shear stress for MPa. Under this pressure, find the torque
the shaft, bolt and key are 50 MPa. The capacity of the clutch. (4)
bearing stress for bolt and key are 50 MPa
and shear stress for CI is 8 MPa. The 69. A power screw is made with Acme
basic dimensions of the coupling may be threads 34 mm-6 mm, single start to lift
assumed as per the standard. Design the and lower a load of 10 kN. The screw and
nut are well lubricated. Sliding friction is
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 MD - IES CONVENTIONAL 1995-2015

0.15 and rolling friction is 0.02. Take 73. A 5 cm dia. solid shaft is welded to a flat
semi thread angle as 14.50. Determine: plate by 1 cm fillet weld. What will be the
(10) max. torque that the welded joint can
(i) Raising Torque sustain if the permissible shear stress in
(ii) Lowering Torque the weld material is not to exceed 8
(iii) Efficiency of the power kN/cm2. Deduce the expression for the
screw shear stress at the throat from the basic
theory. (4)
70. Design a gib and cotter joint for two rods
of square cross section transmitting an
axial tensile load of 40 kN. The gib, cotter 74. A hydrostatic conical bearing is shown in
and rods are made of same material the figure. Show that the load carrying
having allowable tensile strength of 120 capacity of the bearing is given by
MPa and shear strength of 60 MPa and
crushing strength of 160 MPa. Assume
the thickness of cotter as one-third of side
of the square cross section. (10)

71. A 3600 hydrodynamic bearing has a and the flow requirement is given by,
journal diameter of 60 mm and length 60
mm. It is running at a speed of 1200 rpm.
The radial clearance is 0.04 mm and
minimum oil thickness is 0.008 mm. (15)
Sommerfeld number is 0.0446. Find the
viscosity of the oil suitable for the 75. Explain the concept of real and apparent
bearing. (10) areas of contact. Write the formula for
each. (10)
2015
72. A single plate clutch is designed to
transmit 10 kW power at 2000 rpm. The
equivalent mass and radius of gyration of
the input shaft are 20 kg and 75 mm
respectively. The equivalent mass and
radius of gyration of the output shaft are
35 kg and 125 mm respectively.
Calculate:
The time required to bring the output
shaft to the rated speed from rest. (4)