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 factors to be considered in deciding the factor of safety [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 shafts [CO2,K2]
4. What is a self actuating or self energizing brake? When a brake becomes a self locking? [CO2,K2]
5. How the bolt is designated? [CO3,K2]
6. Name the stresses induced in welded joints. [CO3,K2]
7. Define the term nipping in leaf springs [CO4,K2]
8. List out the required qualities of a good friction materials used in clutches. [CO4,K2]
9. Rolling bearing are antifriction bearing- Justify the statement [CO5,K2]
10. State the purpose of flywheel. [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) The frame of a hydraulic press consisting of two identical steel plates is shown
in Fig. The maximum force P acting on the frame is 20 kN. The plates are made of
steel 45C8 with tensile yield strength of 380 N/mm2. The factor of safety is 2.5.
Determine the plate thickness.
 (Or)
11. b. A machine component is subjected to fluctuating stress that varies from 40 [CO1,K3]
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/mm2 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.

ii). A forged steel bar, 50 mm in diameter, is subjected to a reversed bending

stress of 250 N/mm2. The bar is made of steel 40C8 (Sut= 600 N/mm 2).
Calculate the life of the bar for a reliability of 90%.

12. a. i) A line shaft supporting two pulleys A and B is shown in Fig. Power is [CO2,K3]
supplied to the shaft by means of a vertical belt on the pulley A, which is
then transmitted to the pulley B carrying a horizontal belt. The ratio of belt
tension on tight and loose sides is 3:1. The limiting value of tension in the
belts is 2.7 kN. The shaft is made of plain carbon steel 40C8 (S ut= 650
N/mm2 and Syt = 380 N/mm2). The pulleys are keyed to the shaft.
Determine the diameter
of the shaft according to the ASME code if, kb = 1.5 and kt = 1.0

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]
(a). The brake drum rotates at 100 rpm and the coefficient of friction is 0.35.
 Calculate
(1) the actuating force and the hinge-pin reaction for clockwise rotation of
the drum;
(2) the actuating force and hinge-pin reaction for anticlockwise rotation of
the drum;
(3) the rate of heat generated during the braking action; and
(4) 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) An automotive type internal expanding double-shoe brake is shown in

Fig.
The face width of the friction lining is 40 mm and the maximum intensity of
normal pressure is limited to 1 N/mm 2. The coefficient of friction is 0.32.
The angle θ1 can be assumed to be zero. Calculate:
(i) the actuating force P; and
(ii) the torque-absorbing capacity of the brake.

13. a. i) A wall bracket is attached to the wall by means of four identical bolts, two at A and two [CO3,K3]
at B, as shown in Fig. 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 46 N/mm2, determine the size of the bolts on the basis of maximum principal
stress theory.
 ii) A steel bracket is fixed to a vertical support by three bolts. The
dimensions given in figures are in mm. The bolts are made of plain carbon
steel 45C8 (σyt = 380 N/mm2) and factor of safety is 2.5. Determine the size
of bolt

(Or)
13. b. i) A beam of rectangular cross section is welded to a support by means of [CO3,K3]
fillet welds as shown in Fig. Determine the size of the welds, if the
permissible shear stress in the weld is limited to 75 N/mm2.

ii) An ISA 200 x 100 x 10 angle is welded to a steel plate by means of fillet
welds as shown in Fig. The angle is subjected to a static force of 150 kN and
the permissible shear stress for the weld is 70 N/mm2. Determine the
lengths of weld at the top and bottom.
14. a. i) It is required to design a helical compression spring subjected to a [CO4,K3]
maximum force of 1250N. The deflection of the spring corresponding to the
maximum force should be approximately 30 mm. The spring index can be
taken as 6. The spring is made of patented and cold-drawn steel wire. The
ultimate tensile strength and modulus of rigidity of the spring material are
1090 and 81370 N/mm2 respectively. The permissible shear stress for the
spring wire should be taken as 50% of the ultimate tensile strength. Design
the spring and calculate:
(1) wire diameter;
(2) mean coil diameter;
(3) number of active coils;
(4) total number of coils;
(5) free length of the spring; and
(6) 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
leaves including the master leaf. The centre to centre distance between the
spring eyes are 1.2 m. The leaves are made of steel 55Si2Mo90 (σyt = 1500
MPa and E = 207 GPa) and 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
1) the cross section of leaves
2) the deflection at the end of the spring
3) initial nip when the width is 9 times the thickness
(Or)
14 b. i) A multi-disk clutch consists of five steel plates and four bronze plates. [CO4,K3]
The inner and outer diameters of the friction disks are 75 and 150 mm
respectively. The coefficient of friction is 0.1 and the intensity of pressure on
friction lining
is limited to 0.3 N/mm2. Assuming uniform wear theory, calculate:
(1) the required force to engage the clutch; and
(2) power transmitting capacity at 750 rpm.

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:
(1) the inner and outer diameters;
(2) the face width of friction lining;
(3) the force required to engage the clutch; and
(4) the amount of heat generated during each engagement of clutch.

15 a. i) A single-row deep groove ball bearing is subjected to a radial force of 8 [CO5,K3]

kN and a thrust force of 3 kN. The shaft rotates at 1200 rpm. The expected
life L10h of the bearing is 20 000 h. The minimum acceptable diameter of
the shaft is 75 mm. Select a suitable ball bearing for this application.

ii) The following data is given for a hydrostatic thrust bearing:

thrust load = 500 kN
shaft speed = 720 rpm
shaft diameter = 500 mm
recess diameter = 300 mm
film thickness = 0.15 mm
viscosity of lubricant = 160 SUS
specific gravity = 0.86
Calculate
(1) supply pressure;
(2) flow requirement in litres/min;
(3) power loss in pumping; and
(4) frictional power loss.
(Or)
b. i) A machine is driven by a motor, which exerts a constant torque. The [CO5,K3]
resisting torque of the machine increases uniformly from 500 N-m to 1500
N-m through a 360° rotation of the driving shaft and drops suddenly to 500
N-m again at the beginning of the next revolution. The mean angular
velocity of the machine is 30 rad/s and the coefficient of speed fluctuations
is 0.2. A solid circular steel disk, 25 mm thick, is used as flywheel. The mass
density of steel is 7800 kg/m3 while Poisson’s ratio is 0.3. Calculate the
outer radius of the flywheel disk and the maximum stresses induced in it.

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.
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