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. Differentiate shaft and axle [CO2,K2]
4. What is a self actuating or self energizing brake? When a brake becomes a self locking? [CO2,K2]
5. Write any four advantages of bolted joints [CO3,K2]
6. Name the stresses induced in welded joints. [CO3,K2]
7. What do you meant by nipping in springs? [CO4,K2]
8. List out the required qualities of a good friction materials used in clutches. [CO4,K2]
9. State the meaning of L10 life of a bearing [CO5,K2]
10. Define coefficient of fluctuation of speed. [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 [CO1,K3]
cross-section is twice of the width. The force P acting on the bracket at 600 to the
vertical is 5 kN. The material of the bracket is grey cast iron FG 200 and the factor
of safety is 3.5. Determine the dimensions of the cross-section of the
bracket.Assume maximum normal stress theory of failure.

ii) The frame of a hacksaw is shown in Fig. 4.26(a). The initial tension P in the
blade
should be 300 N. The frame is made of plain carbon steel 30C8 with tensile yield
strength of 400 N/mm2 and the factor of safety is 2.5. The cross section of the
frame is rectangular with a ratio of depth to width as 3, as shown in Fig.
Determine the dimensions of the cross-section.
 (Or)
11. b. i) A cantilever beam made of cold drawn steel 4OC8 (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 90 N/mm2. The corrected endurance limit stress for the machine
component is 290 N/mm2. The ultimate tensile strength and yield strength
of the material are 560 and 400 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) The layout of a transmission shaft carrying two pulleys B and C and [CO2,K3]
supported on bearings A and D is shown in Fig. Power is supplied to the
shaft by means of a vertical belt on the pulley B, which is then transmitted
to the pulley C carrying a horizontal belt. The maximum tension in the belt
on the pulley B is 2.5 kN. The angle of wrap for both the pulleys is 180° and
the coefficient of friction is 0.24. The shaft is made of plain carbon steel 30C8
(Syt = 400 N/mm2) and the factor of safety is 3. Determine the shaft diameter
on strength basis.
 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 double shoe brake shown in Fig is having a diameter of brake drum [CO2,K3]
400 mm and angle of contact of each shoe is 100°. The brake is capable of
absorbing a torque of 1XXX (XXX- Last 3 digits of your roll No.) N-m.
The coefficient of friction between brake and lining is 0.35. If the
permissible bearing pressure on the lining material is 1.5 MPa, then
determine the width of the shoes.

ii) A single block brake with a torque capacity of 250 N-m is shown in Fig.
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.
13. a. i) A steel plate subjected to a force of 5 kN and fixed to a channel by means [CO3,K3]
of three identical bolts is shown in Fig. The bolts are made from plain
carbon steel 45C8 (Syt = 380N/mm2) and the factor of safety is 3. Specify the
size of bolts.

ii) A wall bracket is attached to the wall by means of four identical bolts,
two 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.

(Or)
13. b. i) A plate, 75 mm wide and 10 mm thick, is joined with another steel plate [CO3,K3]
by means of single transverse and double parallel fillet welds, as shown in
Fig. The joint is subjected to a maximum tensile force of 55 kN. The
permissible tensile and shear stresses in the weld material are 70 and 50
N/mm2 respectively. Determine the required length of each parallel fillet
weld.
 ii) A bracket is welded to the vertical column by means of two fillet welds
as shown in Fig. Determine the size of the welds, if the permissible shear
stress in the weld is limited to 70 N/mm2.

14. a. i) A helical compression spring, made of circular wire, is subjected to an axial [CO4,K3]
force, which varies from 2.5 kN to 3.5 kN. Over this range of force, the deflection
of the spring should be approximately 5 mm. The spring index can be taken as 5.
The spring has square and ground ends. The spring is made of patented and cold-
drawn steel wire with ultimate tensile strength of 1050 N/mm 2 and modulus of
rigidity of 81370 N/mm2. The permissible shear stress for the spring wire should
be taken as 50% of the ultimate tensile strength. Design the spring and calculate
(a) wire diameter;
(b) mean coil diameter;
(c) number of active coils;
(d) total number of coils;
(e) solid length of the spring;
(f) free length of the spring;
(g) required spring rate; and
(h) actual spring rate

ii) A semi-elliptic leaf spring used for automobile suspension consists of

three extra full-length leaves and 15 graduated-length leaves, including the
master leaf. The centre-to-centre distance between two eyes of the spring is
1 m. The
maximum force that can act on the spring is 75 kN. For each leaf, the ratio
of width to thickness is 9:1. The modulus of elasticity of the leaf material is
207 000 N/mm2. The leaves are pre-stressed in such a way that when the
force is maximum, the stresses induced in all leaves are same and equal to
450 N/mm2.
 Determine
(a) the width and thickness of the leaves;
(b) the initial nip; and
(c) the initial pre-load required to close the gap C between extra full-length
leaves and graduated-length leaves.
(Or)
14 b. i) A single plate clutch consists of only one pair of contacting surfaces. It is [CO4,K3]
used for an engine, which develops a maximum torque of 120 N-m. Assume
a factor of safety of 1.5 to account for slippage at full-engine torque. The
permissible intensity of pressure is 350 kPa and the coefficient of friction is
0.35. Assuming uniform wear theory, calculate the inner and outer
diameters of the friction lining.

ii) A cone clutch with asbestos friction lining transmits 30 kW power at 500
rpm. The coefficient of friction is 0.2 and the permissible intensity of
pressure is 0.35 N/mm2. The semi-cone angle α is 12.5°. The outer diameter
is fixed as 300 mm from space limitations. Assuming uniform wear theory,
calculate:
(a) the inner diameter;
(b) the face width of the friction lining; and
(c) the force required to engage the 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) 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
(a) supply pressure;
(b) flow requirement in litres/min;
(c) power loss in pumping; and
(d) 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.

Bloom’s Remembering Understanding Applying Analyzing Evaluating Creating

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