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. List any four factors influencing machine design [CO1,K1]

2. Draw Goodman and Soderberg line and locate safe design region [CO1,K2]
3. Mention the reasons for preferring hollow shafts over solid shaft. [CO2,K2]
4. When a brake becomes a self locking? [CO2,K2]
5. Mention the condition of bolt for uniform strength [CO3,K2]
6. If the size of the weld is 15 mm. Determine the throat thickness. [CO3,K2]
7. Compare the term spring constant and spring index. [CO4,K2]
8. List out the required qualities of a good friction materials used in clutches. [CO4,K2]
9. What are the requires properties of a bearing materials? [CO5,K2]
10. Enlist the types of stress induced in flywheel rim. [CO5,K2]

PART – B (5 X 16 = 80 Marks)
11. a. i) The frame of a hacksaw is shown in Fig. 4.26(a). The initial tension P in the blade should [CO1,K3]
be 320 N. The frame is made of plain carbon steel 30C8 with tensile yield strength of 440
N/mm2 and the factor of safety is 3.5. The cross section of the frame is rectangular with a
ratio of depth to width as 4, as shown in Fig. Determine the dimensions of the cross-
section.

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 0.8 times of the outer diameter. The
column is made of steel FeE 200 (Syt = 200 N/mm 2) and the factor of safety is 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 = 600 N/mm2 and [CO1,K3]
Syt = 380 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 0.9. Determine the
diameter d of the beam at the fillet cross-section using Gerber curve as
failure criterion.

ii). A machine component is subjected to fluctuating stress that varies from

40 to 100 N/mm2. The corrected endurance limit stress for the machine
component is 270 N/mm2. The ultimate tensile strength and yield strength
of the material are 600 and 450 N/mm 2 respectively. Find the factor of
safety using
(1) Gerber theory
(2) Soderberg line
(3) Goodman line
Also, find the factor of safety against static failure.

12. a. i) A hollow transmission shaft, having inside diameter 0.6 times the outside [CO2,K3]
diameter, is made of plain carbon steel 40C8 (Syt = 380 N/mm2) and the
factor of safety is 3. A belt pulley, 1000 mm in diameter, is mounted on the
shaft, which overhangs the left hand bearing by 250 mm. The belts are
vertical and transmit power to the machine shaft below the pulley. The
tension on the tight and slack sides of the belt are 3 kN and 1 kN
respectively, while the weight of the pulley is 500 N. The angle of wrap of
the belt on the pulley
is 180°. Calculate the outside and inside diameters of the shaft.

ii) It is required to design a square key for fixing a gear on a shaft of 25 mm

diameter. The shaft is transmitting 15 kW power at 720 rpm to the gear. The
 key is made of steel 50C4 (Syt = 460 N/mm2) and the factor of safety is 3.
For key material, the yield strength in compression can be assumed to be
equal to the yield strength in tension. Determine the dimensions of the key.
(Or)
12. b. i) A single block brake with a torque capacity of 250 N-m is shown in Fig. [CO2,K3]
The
brake drum rotates at 100 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 1 N/mm2. The length of the block is twice its
width.
State whether the brake is self-locking.

ii) A differential band brake is shown in Fig. The width and the thickness
of the steel band are 100 mm and 3 mm respectively and the maximum
tensile stress in the band is 50 N/mm2. The coefficient of friction between
the friction lining and the brake drum is 0.25.
Calculate:
(i) the tensions in the band;
(ii) the actuating force; and
(iii) the torque capacity of the brake.
Find out whether the brake is self-locking.

13. a. i) A wall bracket is attached to the wall by means of four identical bolts, two [CO3,K3]
at A and two at B, as shown in Fig. 7.21. Assuming that the bracket is held
against the wall and prevented from tipping about the point C by all four
bolts and using an allowable tensile stress in the bolts as 35 N/mm 2,
determine the size of the bolts on the basis of maximum principal stress
theory.
 ii) A bracket is fastened to the steel structure by means of six identical bolts
as shown in Fig. Assume the following data:
l1 = 300 mm l2 = 200 mm l3 = 100 mm
l = 250 mm P = 50 kN
Neglecting shear stress, determine the size of thebolts, if the maximum
permissible tensile stress in any bolt is limited to 100 N/mm2.

(Or)
13. b. i) A steel plate, 100 mm wide and 10 mm thick, is joined with another steel [CO3,K3]
plate by means of single transverse and double parallel fillet welds, as
shown in Fig. The strength of the welded joint should be equal to the
strength of the plates to be joined. The permissible tensile and shear stresses
for the weld material and the plates are 70 and 50 N/mm 2 respectively.
Find the length of each parallel fillet weld. Assume the tensile force acting
on the plates as static.

ii) A welded connection, as shown in Fig is subjected to an eccentric force of

7.5 kN. Determine the size of welds if the permissible shear stress for the
weld is 100 N/mm2. Assume static conditions.
14. a. i) A safety valve, 50 mm in diameter, is to blow off at a pressure of 1.5 MPa. [CO4,K3]
It is held on its seat by means of a helical compression spring, with an initial
compression of 25 mm. The maximum lift of the valve is 10 mm. The spring
index can be taken as 6. The spring is made of patented and cold-drawn
steel wire with ultimate tensile strength of 1500 N/mm2 and modulus of
rigidity of 81 370 N/mm2. The permissible shear stress for the spring wire
should be taken as 30% of the ultimate tensile strength. Design the spring
and calculate:
(i) wire diameter;
(ii) mean coil diameter;
(iii) number of active turns;
(iv) total number of turns;
(v) solid length;
(vi) free length; and
(vii) pitch of the coil.

ii) A semi-elliptic multi-leaf spring is used for the suspension of the rear
axle of a truck. It consists of two extra full-length leaves and ten graduated-
length leaves including the master leaf. The centre-to-centre distance
between the
spring eyes is 1.2 m. The leaves are made of steel 55Si2Mo90 (Syt = 1500
N/mm2 and E = 207 000 N/mm2) and the factor of safety is 2.5. The spring
is
to be designed for a maximum force of 30 kN. The leaves are pre-stressed so
as to equalize stresses in all leaves. Determine
(i) the cross-section of leaves; and
(ii) the deflection at the end of the spring.
(Or)
14 b. i) An automotive plate clutch consists of two pairs of contacting surfaces [CO4,K3]
with
an asbestos friction lining. The torque transmitting capacity of the clutch is
550 N-m. The coefficient of friction is 0.25 and the permissible intensity of
pressure is 0.5 N/mm2. Due to space limitations, the outer diameter of the
friction disk is fixed as 250 mm. Using uniform wear theory, calculate
(i) the inner diameter of the friction disk; and
(ii) the spring force required to keep the clutch
in an engaged position.
 ii) A cone clutch is used to connect an electric motor running at 1440 rpm
with a machine which is stationary. The machine is equivalent to a rotor of
150 kg mass and radius of gyration as 250 mm. The machine has to be
brought to the full speed of 1440 rpm from stationary condition in 40s. The
semi-cone angle  is 12.5°. The mean radius of the clutch is twice the face
width. The coefficient of friction is 0.2 and the normal intensity of pressure
between contacting surfaces should not exceed 0.1 N/mm2. Assuming
uniform wear criterion, calculate:
(i) the inner and outer diameters;
(ii) the face width of friction lining;
(iii) the force required to engage the clutch; and
(iv) the amount of heat generated during each
engagement of clutch.

15 a. i) A single-row deep groove ball bearing has a dynamic load capacity of [CO5,K3]
40500 N and operates on the following work cycle:
(a) radial load of 5000 N at 500 rpm for 25% of the time;
(b) radial load of 10000 N at 700 rpm for 50% of the time; and
(c) radial load of 7000 N at 400 rpm for the remaining 25% of the time.
Calculate the expected life of the bearing in hours.

ii) A single-row deep groove ball bearing is subjected to a 30 second work

cycle that consists of the following two parts:
Part I Part II
duration (s) 10 20
radial load (kN) 45 15
axial load (kN) 12.5 6.25
speed (rpm) 720 1440
The static and dynamic load capacities of the ball bearing are 50 and 68 kN
respectively. Calculate the expected life of the bearing in hours.
(Or)
b. i) The torque developed by an engine is given by the following equation: [CO5,K3]
T = 14 250 + 2200 sin 2θ – 1800 cos 2 θ
where T is the torque in N-m and θ is the crank angle from the inner dead
centre position. The resisting torque of the machine is constant throughout
the
work cycle. The coefficient of speed fluctuations is 0.01. The engine speed is
150 rpm. A solid circular steel disk, 50 mm thick, is used as a flywheel. The
mass density of steel is 7800 kg/m3. Calculate the radius of the flywheel
disk.

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 = 250 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 10% of
the required moment of inertia. The rim has rectangular cross-section and
the ratio of width to thickness is 1.5. Determine the dimensions of the rim.

Bloom’s Remembering Understanding Applying Analyzing Evaluating Creating

Taxonomy (K1) (K2) (K3) (K4) (K5) (K6)
Level
Percentage