Register No.

BE/B.Tech Degree Examination , May 2024

Sixth Semester

20MET63 – DESIGN OF MACHINE ELEMENTS

(Regulations 2020)

Time : Three hours Maximum : 100 Marks

Answer all Questions

PART – A (10 X 2 = 20 Marks)

1. What are the various phases of design process? [CO1,K1]

2. State various methods of finding stress concentration fctor. [CO1,K2]
3. Classify the types of shafts. [CO2,K2]
4. How does the function of a brake differ from that of a clutch? [CO2,K2]
5. How is the bolt designated? [CO3,K2]
6. Write down the formula for the strength of a single transverse fillet weld. [CO3,K2]
7. How will you find whether the given helical spring is a compression spring or tensile spring? [CO4,K2]
8. Clutches are usually designed on the basis of uniform wear. Why? [CO4,K2]
9. How is sommerfeld number calculated? [CO5,K2]
10. How does a flywheel differ from a governor? [CO5,K2]

PART – B (5 X 16 = 80 Marks)
11. a. i) A wall bracket with a rectangular cross-section is shown in Fig. The depth of the cross- [CO1,K3]
section is twice of the width. The force P acting on the bracket at 60° to the vertical is 8 kN.
The material of the bracket is grey cast iron FG 200 and the factor of safety is 2.5.
Determine the dimensions of the cross-section of the bracket. Assume maximum normal
stress theory of failure.

ii) A hollow circular column carries a projecting bracket, which supports a load of 25 kN
as shown in Fig. The distance between the axis of the column and the load is 500 mm. The
inner diameter of the column is 0.52 times of the outer diameter. The column is made of
steel FeE 200 (Syt = 307 N/mm 2) and the factor of safety is 5.4. The column is to be
designed on the basis of maximum tensile stress and compression is not the criterion of
failure. Determine the dimensions of the cross-section of the column.
 (Or)
11. b. i) A cantilever beam made of cold drawn steel 40C8 (Sut = 509 N/mm 2 and Syt = 388 [CO1,K3]
N/mm2) is shown in Fig. The force P acting at the free end varies from –50 N to +150 N.
The expected reliability is 90% and the factor of safety is 2. The notch sensitivity factor at
the fillet is 0.63. Determine the diameter d of the beam at the fillet cross-section using
Gerber curve as failure criterion.

ii). A transmission shaft of cold drawn steel 27Mn2 (S ut = 490 N/mm2 and Syt = 290
N/mm2) is subjected to a fluctuating torque which varies from –106 N-m to + 405 N-m. The
factor of safety is 3.2 and the expected reliability is 90%. Neglecting the effect of stress
concentration, determine the diameter of the shaft. Assume the distortion energy theory of
failure.

12. a. i) The layout of a shaft carrying two pulleys 1 and 2, and supported on two bearings A and [CO2,K3]
B is shown in Fig. The shaft transmits 9.5 kW power at 460 rpm from the pulley 1 to the
pulley 2. The diameters of pulleys 1 and 2 are 250 mm and 500 mm respectively. The
masses of pulleys 1 and 2 are 10 kg and 30 kg respectively. The belt tensions act vertically
downward and the ratio of belt tensions on the tight side to slack side for each pulley is
4.5:1. The shaft is made of plain carbon steel 40C8 (S yt = 350 N/mm 2) and the factor of
safety is 3.47. Estimate suitable diameter of shaft. If the permissible angle of twist is 0.5°
per metre length, calculate the shaft diameter on the basis of torsional rigidity. Assume G
= 78800 N/mm2.

ii) Design a woodruff key to transmit 6kW power at 302 rpm. The key is made of C45 steel
and the factor of safety is 6.2.
(Or)
12. b. i) A single block brake with a torque capacity of 550 N-m is shown in Fig. The [CO2,K3]
brake drum rotates at 107 rpm and the coefficient of friction is 0.35. Calculate
(a) the actuating force and the hinge-pin reaction for clockwise rotation of the drum;
 (b) the actuating force and hinge-pin reaction for anticlockwise rotation of the drum;
(c) the rate of heat generated during the braking action; and
(d) the dimensions of the block, if the intensity of pressure between the block and brake
drum is 2.6 N/mm2. The length of the block is twice its width.
State whether the brake is self-locking.

ii) The Following Fig. shows the arrangement of two brake shoes which act on the internal
surface of a cylindrical brake drum. The braking force F 1 and F2 are applied as shown and
each shoe pivots on its fulcrum O 1 and O2. The width of the brake lining is 35 mm. The
intensity of pressure at any point A is 0.5 N/mm 2. The coefficient of friction is 0.45.
Determine the braking torque and the magnitude of the forces F1 and F2.

13. a. i) A bracket as shown in Fig. is fitted to a wall with 5 bolts, three at the top and two at the [CO3,K3]
bottom, with all bolts equally spaced. A load of 20000 N is acting at an eccentricity of 200
mm. Vertical distance of first and second rows from the hinge point are 50 mm and 250
mm respectively. Select a suitable size of the bolt.

ii) Find suitable bolt for the application shown in Fig.

 (Or)
13. b. i) A shaft of rectangular cross section is welded to a support plate by means of fillet weld [CO3,K3]
on its one end as shown in Fig. The other end is loaded by 25 kN. If the size of the weld is 8
mm, find the maximum normal and shear stress in the weld

ii) A bracket shown in Fig. carries a load of 10 kN. Find the size of weld if the allowable
shear stress is not to exceed 95 MPa.

14. a. i) A helical spring made of C50 steel has an outside diameter of 88 mm and a wire diameter [CO4,K3]
of 13.8 mm. The spring has to support a maximum load of 1.5 kN. Determine the
maximum shear stress and total deflection. If the springs have 10.5 coils with ends ground
flat. Determine also the factor of safety. Take G = 0.89 x102kN/mm2

ii) A railway wagon moving at a velocity of 3.5 m/s is brought to rest by a bumper
consisting of two helical springs arranged in parallel. The mass of the wagon is 1555 kg.
The springs are compressed by 155 mm in bringing the wagon to rest. The spring index can
be taken as 6. The springs are made of oil-hardened and tempered steel wire with ultimate
tensile strength of 1255 N/mm2 and modulus of rigidity of 81 370 N/mm 2. The permissible
shear stress for the spring wire can be taken as 50% of the ultimate tensile strength.
Design the spring and calculate:
(i) wire diameter; (ii) mean coil diameter; (iii) number of active coils; (iv) total number of
coils;
(v) solid length; (vi) free length; (vii) pitch of the coil; (viii) required spring rate; and
(ix) actual spring rate.
 (Or)
14 b. i) A multiplate disc clutch transmits 75 kW of power at 1888 rpm. Coefficient of friction for [CO4,K3]
the friction surfaces is 0.1. Axial intensity of pressure is not to exceed 175 kN/m 2. The
internal radius is 70 mm and is 0.74 times the external radius. Find the number of plates
needed to transmit the required torque.

ii) A cone clutch with a semi-cone angle  is 15°transmits 16kW at 700 rpm. The normal
pressure between the surfaces in contact is not to exceed 1011 kN/m 2. The width of the
friction surfaces is half of the mean diameter. Assume µ = 0.45. Determine
(i) the inner and outer diameters of the plate;
(ii) the axial force required to engage the clutch; and

15 a. i) Design a journal bearing for 13 MW, 1111 rpm steam turbine which is supported by two [CO5,K3]
bearings. Take the atmospheric temperature as 16°C and operating temperature of oil is
60°C. Assume viscosity of oil as 26 centistokes.

ii) A single row deep groove ball bearing is subjected to the following work cycles.
Sl. No Fraction Radial load Axial load Speed Service
of cycle Fr in kN Fa in kN (rpm) Factor

1 1/10 2500 1200 400 3.0

2 1/10 1550 1055 500 1.5
3 1/5 1050 1555 600 2.0
4 3/5 1100 2055 800 1.0

If the desired rating life is 15,000 hours, select one bearing from the following data
Bearing No 6015 6215 6315 6415
Dynamic Capacity ‘C’ kN 31 52 90 120
Assume radial and axial load factors to be 1.0 and 1.5 respectively and inner race rotates.
(Or)
b. i) Design a rim type CI flywheel for an IC engine to store 10,111 N-m of energy. The speed [CO5,K3]
of the engine is to be 500 + 2.5 %. Assume suitable stress value.

ii) The turning moment diagram of a multi-cylinder engine is drawn with a scale of (1 mm
= 1°) on the abscissa and (1 mm = 420 N-m) on the ordinate. The intercepted areas between
the torque developed by the engine and the mean resisting torque of the machine, taken in
order from one end are – 350, + 800, – 600, + 900, – 550, + 450 and –650 mm 2. The engine is
running at a mean speed of 750 rpm and the coefficient of speed fluctuations is limited to
0.02. A rimmed flywheel made of grey cast iron FG 200 (ρ= 7100 kg/m 3) is provided. The
spokes, hub and shaft are assumed to contribute 20% of the required moment of inertia.
The rim has rectangular cross-section and the ratio of width to thickness is 3.5. Determine
the dimensions of the rim.