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VALLIAMMAI ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING

ME6503 DESIGN OF MACHINE ELEMENTS QUESTION BANK

Unit -1 STEADY STRESSES AND VARIABLE STRESSES IN MACHINE MEMBERS

Part-A

1. What are the steps in machine design process?

2. How will you classify machined design and explain it?
3. Enumerate the most commonly used engineering materials and state at least one
important property and one application of each
4. Why are metals in their pure form unsuitable for industrial use?
5. Define mechanical property of an engineering material. State any six mechanical
properties give their definitions and one example of the material possessing the
properties.
6. What are fits and tolerances? How are they designated
7. What do you understand by the nominal size and basic size?
8. Write short notes on the following:
a. Interchangeability
b. Tolerance
c. Allowance and
d. Fits
9. What is the difference in the type of assembly generally used in running fits and
interference fits?
10. Define unilateral and bilateral tolerance.
11. What is meant by hole basis system and shaft basic system? Which one is
preferred and why?
12. Discuss the Indian standard system of limits and fits.
13. What are the commonly used fits according to Indian standards?
14. What do you understand by preferred numbers?
15. Write soderberg equation for a machine component subjected to
a. Combination of mean and variable torques
b. Combination of mean and variable bending moments.
16. How is the working stress calculated from the yield stress of a material?
17. What is meant by stress concentration? How do you take it into consideration in case
of a component subjected to dynamic loading?
18. For Ductile material, which of the strength is considered for designing a
a. Component subjected to static loading
b. Component subjected to fatigue loading
19. What is Gerber Theory?
20. What is the force required to punch a hole of diameter d in a metal of thickness t
having ultimate shear strength as u?

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Part-B

1. The frame of a punch press is shown in Fig. 5.9. Find the stresses at the inner and
outer surface at section X-X of the frame, if W = 5000 N.

2 The crank hook carries a load of 20 KN as shown in FIG.(2).This section at X-

X is rectangular whose horizontal side is 100mm. Find the stresses in the inner
and outer fibers at the given section

3. The load on a bolt consists of an axial pull of 10kN together with a transverse shear
force of 5Kn. Find the diameter of bolt required according to

1. Maximum principal stress theory; 2. Maximum shear stress theory; 3. Maximum

principal strain theory; 4. Maximum strain energy theory and 5. Maximum distortion
energy theory.

4. A bar of circular cross section is subjected to alternating tensile forces varying

from a minimum of 200KN to a maximum of 500KN. It is to be manufactured of
material with an ultimate tensile strength of 900Mpa and an endurance limit of
700Mpa. Determine the diameter of bar using safety factors of 3.5 related to
ultimate tensile strength and 4 related to endurance limit and stress concentration
factor of 1.65 for a fatigue load. Use Goodman straight line as basis for design.

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5. An overhang crank with pin and shaft is shown in Fig. 5.18. A tangential load of 15
kN acts on the crank pin. Determine the maximum principal stress and the maximum
shear stress at the centre of the crankshaft bearing.

6. A mild steel bracket as shown in fig. (1) is subjected to a pull of 6000N acting at
450 to its horizontal axis. The bracket has a rectangular section whose depth is twice
the thickness. Find the cross sectional dimensions of the bracket, if the permissible
stress in the material of the bracket is limited to 60 MPa.

7. Find the maximum stress induced in the following cases taking stress concentration
into account:
1. A rectangular plate 60 mm 10 mm with a hole 12 diameter as shown in Fig. (a)
and subjected to a tensile load of 12 kN.
2. A stepped shaft as shown in Fig. (b) and carrying a tensile load of 12 kN.

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8. A leaf spring in an automobile is subjected to cyclic stresses. The average stress = 150
MPa; variable stress = 500 MPa; ultimate stress = 630 MPa; yield point stress = 350
MPa and endurance limit = 150 MPa. Estimate, under what factor of safety the spring
is working, by Goodman and Soderberg formulae.

9. A steel connecting rod is subjected to a completely reversed axial load of 160 kN.
Suggest the suitable diameter of the rod using a factor of safety 2. The ultimate tensile
strength of the material is 1100 MPa, and yield strength 930 MPa. Neglect column
action and the effect of stress concentration.

10. A pulley is keyed to a shaft midway between two anti-friction bearings. The bending
moment at the pulley varies from 170 N-m to 510 N-m and the torsional moment in
the shaft varies from 55 N-m to 165 N-m. The frequency of the variation of the loads
is the same as the shaft speed. The shaft is made of cold drawn steel having an
ultimate strength of 540 MPa and a yield strength of 400 MPa. Determine the required
diameter for an indefinite life. The stress concentration factor for the keyway in
bending and torsion may be taken as 1.6 and 1.3 respectively. The factor of safety is
1.5. Take size factor = 0.85 and surface finish factor = 0.88.

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Unit-II SHAFTS AND COUPLINGS

Part-A

1. Distinguish clearly, giving examples between pin, axle and shaft.

2. How the shafts are formed?
3. Discuss the various types of shafts and the standard sizes of transmissions
shafts.
4. What types of stresses are induced in shafts?
5. How the shaft is designed when it is subjected to twisting moment only?
6. Define equivalent twisting moment and equivalent bending moment. State
when these two terms are used in design of shafts.
7. When the shaft is subjected to fluctuating loads, what will be the equivalent
twisting moment and equivalent bending moment?
8. What do you understand by torsional rigidity and lateral rigidity?
9. A hollow shaft has greater strength and stiffness than solid shaft of equal
weight. Explain.
10. Under what circumstances are hollow shafts preferred over solid shafts? Give
any two examples where hollow shafts are used. How they are generally
manufactured?
11. What is a key? State its function.
12. How are the keys classified? Draw neat sketches of different types of keys and
state their applications.
13. What are the considerations in the design of dimensions of formed and parallel
key having rectangular cross-section?
14. Write short note on the splined shaft covering the points of application,
different types and method of manufacture.
15. What is the effect of keyway cut into the shaft?
16. Discuss the function of a coupling. Give at least three practical applications.
17. How does the working of a clamp coupling differ from that of a muff
coupling? Explain.
18. Sketch a protective type flange coupling and indicate there on its leading
dimensions for shaft size of d.
19. What are flexible couplings and what are their applications? Illustrate your
answer with suitable examples and sketches.
20. Why are two universal joints often used when there is angular misalignment
between two shafts?

Part-B

1. A hollow steel shaft transmits 600 kW at 500 r.p.m. The maximum shear stress is 62.4
MPa. Find the outside and inside diameter of the shaft, if the outer diameter is twice
of inside diameter, assuming that the maximum torque is 20% greater than the mean
torque.

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2. Two 400 mm diameter pulleys are keyed to a simply supported shaft 500 mm apart.
Each pulley is 100 mm from its support and has horizontal belts, tension ratio being
2.5. If the shear stress is to be limited to 80 MPa while transmitting 45 kW at 900
r.p.m., find the shaft diameter if it is to be used for the input-output belts being on the
same or opposite sides.

3. Fig. 14.17 shows a shaft from a hand-operated machine. The frictional torque in the
journal bearings at A and B is 15 N-m each. Find the diameter ( d ) of the shaft (on
which the pulley is mounted) using maximum distortion energy criterion. The shaft
material is 40 C 8 steel for which the yield stress in tension is 380 MPa and the factor
of safety is 1.5.

4. A shaft made of steel receives 7.5 kW power at 1500 r.p.m. A pulley mounted on the
shaft as shown in Fig. 14.19 has ratio of belt tensions 4.
The gear forces are as follows: Ft = 1590 N; Fr = 580 N
Design the shaft diameter by maximum shear stress theory. The shaft material has the
following properties: Ultimate tensile strength = 720 MPa; Yield strength = 380 MPa;
Factor of safety = 1.5.

5. The internal diameter of a hollow shaft is 2/3 rd of its external diameter. Compare the
strength and stiffness of the shaft with that of a solid shaft of the same material.

6. The shaft of an axial flow rotary compressor is subjected to a maximum torque of

2000 N-m and a maximum bending moment of 4000 N-m. The combined shock and
fatigue factor in torsion is 1.5 and that in bending is 2. Design the diameter of the
shaft, if the shear stress in the shaft is 50 MPa. Design a hollow shaft for the above
compressor taking the ratio of outer diameter to the inner diameter as 2. What is the
percentage saving in material ? Also compare the stiffness.

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7. A steel shaft has a diameter of 25 mm. The shaft rotates at a speed of 600 r.p.m. and
transmits 30 kW through a gear. The tensile and yield strength of the material of shaft
are 650 MPa and 353 MPa respectively. Taking a factor of safety 3, select a suitable
key for the gear. Assume that the key and shaft are made of the same material.

8. Design a cast iron protective flange coupling to connect two shafts in order to transmit
7.5 kW at 720 r.p.m. The following permissible stresses may be used :
Permissible shear stress for shaft, bolt and key material = 33 MPa
Permissible crushing stress for bolt and key material = 60 MPa
Permissible shear stress for the cast iron = 15 MPa

9. Two shafts made of plain carbon steel are connected by a rigid protective type flange
coupling. The shafts are running at 500 r.p.m. and transmit 25 kW power. Design the
coupling completely for overload capacity 25 per cent in excess of mean transmitted
torque capacity. Assume the following permissible stresses for the coupling
components :
Shaft Permissible tensile stress = 60 MPa; Permissible shear stress = 35 MPa
Keys Rectangular formed end sunk key having permissible compressive strength =
60 MPa
Bolts Six numbers made of steel having permissible shear stress = 28 MPa
Flanges Cast iron having permissible shear stress = 12 MPa
Draw two views of the coupling you have designed.

10. A flanged protective type coupling is required to transmit 50 kW at 2000 r.p.m.. Find
:
(a) Shaft diameters if the driving shaft is hollow with di / d0 = 0.6 and driven
shaft is a solid shaft. Take = 100 MPa.
(b) Diameter of bolts, if the coupling uses four bolts. Take c = t = 70 MPa and
= 25 MPa. Assume pitch circle diameter as about 3 times the outside diameter
of the hollow shaft.
(c) Thickness of the flange and diameter of the hub. Assume c = 100 MPa and
= 125 MPa.
(d) Make a neat free hand sketch of the assembled coupling showing a
longitudinal sectional elevation with the main dimensions. The other dimensions
may be assumed suitably.

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Unit III TEMPORARY AND PERMANENT JOINTS

Part-A

1. What do you understand by the single start and double start threads?
2. Discuss on bolts of uniform strength giving examples of practical applications of such
bolts.
3. State three conditions where tap bolts are used.
4. What are the different stresses setups in a bolt due to initial tightening?
5. What is threaded joint?
6. What is a stud?
7. How is a bolt designated? Give examples.
8. How do you design a bolt with uniform strength?
9. What is the meaning of bolt M24 x 2?
10. What is purpose of cotter joint?
11. Which type of thread would you suggest for the following?
a. Lead screw for a lathe
b. Fastening of a bracket to a wall
c. Screw jack.
12. What are the reasons of replacing riveted joint by welded joint in modern equipment?
13. Why reinforcement is normally required in welded joints?
14. What are the advantages of welded joints compared with riveted joints?
15. Write down the expression for strength of parallel fillet weld in terms of permissible
shear stress, leg of weld and length of welded joint.
16. What is the minimum size for fillet weld? If required weld size from strength
consideration is too small how will you fulfil the condition of minimum weld size?
17. Name the possible modes of failure of riveted joint.
18. What do you mean by efficiency of a riveted joint? The efficiency of a riveted joint is
always less than 100% give your comment.
19. Distinguish between cotter joint and knuckle joint.
20. What is a cotter joint? Explain with the help of a neat sketch, how a cotter joint is
made?
Part-B
1. A pulley bracket, as shown in Fig. 11.49, is supported by 4 bolts, two at A-A and two
at B-B. Determine the size of bolts using an allowable shear stress of 25 MPa for the
material of the bolts.

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2. A wall bracket, as shown in Fig. 11.50, is fixed to a wall by means of four bolts. Find
the size of the bolts and the width of bracket. The safe stress in tension for the bolt
and bracket may be assumed as 70 MPa.

3. A bracket is bolted to a column by 6 bolts of equal size as shown in Fig. 11.51. It

carries a load of 50 kN at a distance of 150 mm from the centre of column. If the
maximum stress in the bolts is to be limited to 150 MPa, determine the diameter of
bolt.

4. A bracket, as shown in Fig. 11.53, is fixed to a vertical steel column by means of five
standard bolts. Determine : (a) The diameter of the fixing bolts, and (b) The thickness
of the arm of the bracket. Assume safe working stresses of 70 MPa in tension and 50
MPa in shear.

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5. Design a cotter joint to connect two mild steel rods for a pull of 30 kN. The maximum
permissible stresses are 55 MPa in tension ; 40 MPa in shear and 70 MPa in crushing.
Draw a neat sketch of the joint designed.
6. Design a knuckle joint to connect two mild steel bars under a tensile load of 25 kN.
The allowable stresses are 65 MPa in tension, 50 MPa in shear and 83 MPa in
crushing.
7. A bracket is riveted to a columm by 6 rivets of equal size as shown in Fig. 9.38. It
carries a load of 100 kN at a distance of 250 mm from the column. If the maximum
shear stress in the rivet is limited to 63 MPa, find the diameter of the rivet.

8. A triple riveted butt joint with equal double cover plates (zig-zag riveting) is used for
the longitudinal joint of a Lancashire boiler of 2.5 m internal diameter. The working
steam pressure is 1.12 N/mm2 and the efficiency of the joint is 85 per cent. Calculate
the plate thickness for mild steel of 460 MPa ultimate tensile strength. Assume ratio
of tensile to shear stresses as 7/6 and factor of safety 4. The resistance of the rivets in
double shear is to be taken as 1.875 times that of single shear. Design a suitable
circumferential joint also.

9. A bracket is welded to the side of a column and carries a vertical load P, as shown in
Fig. 10.38. Evaluate P so that the maximum shear stress in the 10 mm fillet welds is
80 MPa.

10. A bracket, as shown in Fig. 10.39, carries a load of 40 kN. Calculate the size of weld,
if the allowable shear stress is not to exceed 80 MPa.

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Unit-IV ENERGY STORING ELEMENTS AND ENGINE COMPONENTS

Part-A

1. What is the function of a spring? In which type of spring the behaviour is non-linear?
2. Discuss the materials and practical applications for the various types of springs.
3. The extension springs are in considerably less use than the compression springs.
Why?
4. Explain one method of avoiding the tendency of a compression spring to buckle.
5. What do you understand by full length and graduated leaves of a leaf spring? Write
the expression for determining the stress and deflection in full length and graduated
leaves.
6. What is nipping in a leaf spring? Discuss its role. List the materials commonly used
for the manufacture of the leaf springs.
7. What is the effect of increase in wire diameter on the allowable stress value?
8. What are constant widths and constant strength springs?
9. What is meant by coefficient of fluctuation of energy with reference to flywheels?
10. What are the applications of concentric spring?
11. Two springs of stiffness K1 and K2 are connected in series. What is the stiffness of
connection?
12. What are the different styles of end for helical compression spring?
13. When two concentric springs of stiffness 100 N/mm and 50 N/mm respectively are
subjected to an axial load of 750 N, what will be the deflection of each spring?
14. How do you eliminate the surge in springs?
15. What is purpose of leaf spring that is used in automobiles?
16. What type of stresses is produced in a disc flywheel?
17. What is the main function of a flywheel in an engine?
18. In what way does a flywheel differ from that of a governor? Illustrate your answer
with suitable examples.
19. Define coefficient of fluctuation of speed and coefficient of steadiness.
20. Discuss the various types of stresses induced in a flywheel rim.

Part-B
1. Design a compression helical spring to carry a load of 500 N with a deflection of 25
mm. The spring index may be taken as 8. Assume the following values for the spring
material:
Permissible shear stress = 350 MPa
Modulus of rigidity = 84 kN/mm2

2. Design a helical spring for a spring loaded safety valve for the following conditions :
Operating pressure = 1 N/mm2
Maximum pressure when the valve blows off freely = 1.075 N/mm2
Maximum lift of the valve when the pressure is 1.075 N/mm2 = 6 mm
Diameter of valve seat = 100 mm
Maximum shear stress = 400 MPa
Modulus of rigidity = 86 kN/mm2
Spring index = 5.5

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3. A vertical spring loaded valve is required for a compressed air receiver. The valve is
to start opening at a pressure of 1 N/mm2 gauge and must be fully open with a lift of 4
mm at a pressure of 1.2 N/mm2 gauge. The diameter of the port is 25 mm. assume the
allowable shear stress in steel as 480 MPa and shear modulus as 80 kN/mm2.
Design a suitable close coiled round section helical spring having squared ground
ends. Also specify initial compression and free length of the spring.

4. A spring controlled lever is shown in Fig. 23.34. The spring is to be inserted with an
initial compression to produce a force equal to 125 N between the right hand end of
the lever and the stop. When the maximum force at A reaches to a value of 200 N, the
end of the lever moves downward by 25 mm.

Assuming a spring index as 8, determine: 1. spring rate, 2 size of wire, 3. outside

diameter of the spring, 4. number of active coils, and 5. free length, assuming squared
and ground ends. The allowable shear stress may be taken as 420 MPa and G = 80
kN/mm2.

5. A railway wagon weighing 50 kN and moving with a speed of 8 km per hour has to be
stopped by four buffer springs in which the maximum compression allowed is 220
mm. Find the number of turns in each spring of mean diameter 150 mm. The diameter
of spring wire is 25 mm. Take G = 84 kN/mm2.

6. A semi-elliptical spring has ten leaves in all, with the two full length leaves extending
625 mm. It is 62.5 mm wide and 6.25 mm thick. Design a helical spring with mean
diameter of coil 100 mm which will have approximately the same induced stress and
deflection for any load. The Youngs modulus for the material of the semi-elliptical
spring may be taken as 200 kN/mm2 and modulus of rigidity for the material of
helical spring is 80 kN/mm2.

7. Design a leaf spring for the following specifications : Total load = 140 kN ; Number
of springs supporting the load = 4 ; Maximum number of leaves = 10; Span of the
spring = 1000 mm ; Permissible deflection = 80 mm. Take Youngs modulus, E = 200
kN/mm2 and allowable stress in spring material as 600 MPa.

8. Design a cast iron flywheel for a four stroke cycle engine to develop 110 kW at 150
r.p.m. The work done in the power stroke is 1.3 times the average work done during
the whole cycle. Take the mean diameter of the flywheel as 3 metres. The total
fluctuation of speed is limited to 5 per cent of the mean speed. The material density is
7250 kg / m3. The permissible shear stress for the shaft material is 40 MPa and
flexural stress for the arms of the flywheel is 20 MPa.

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9. A punching press is required to punch 40 mm diameter holes in a plate of 15 mm

thickness at the rate of 30 holes per minute. It requires 6 N-m of energy per mm2 of
sheared area. Determine the moment of inertia of the flywheel if the punching takes
one-tenth of a second and the r.p.m. of the flywheel varies from 160 to 140.

10. Design completely the flywheel, shaft and the key for securing the flywheel to the
shaft, for a punching machine having a capacity of producing 30 holes of 20 mm
diameter per minute in steel plate 16 mm thickness. The ultimate shear stress for the
material of the plate is 360 MPa. The actual punching operation estimated to last for a
period of 36 rotation of the punching machine crankshaft. This crank shaft is
powered by a flywheel shaft through a reduction gearing having a ratio 1 : 8. Assume
that the mechanical efficiency of the punching machine is 80% and during the actual
punching operation the flywheel speed is reduced by a maximum of 10%. The
diameter of flywheel is restricted to 0.75 m due to space limitations.

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Unit-V BEARINGS
Part-A
1. What are journal bearings? Give a classification of these bearings.
2. What is meant by hydrodynamic lubrication?
3. Explain wedge film and squeeze film journal bearings.
4. List the important physical characteristics of a good bearing material.
5. What is the procedure followed in designing a journal bearing?
6. For a journal bearing the maximum operating temperature must be less than 80C.
Why?
7. State the merits of hydrostatic bearings.
8. What is a quill bearing?
9. State the disadvantages of trust ball bearing.
10. List any four advantages of rolling contact bearings over sliding contact bearings.
11. What is meant by life of anti-friction bearings?
12. Differentiate the rated life of bearing with its average life.
13. What is the advantage of Telfon which is used for bearings?
14. Name the material that is used for to make ball bearings.
15. Why is piston end of a connecting rod kept smaller than the crank pin end?
16. Explain the various stresses induced in the connecting rod.
17. Under what force, the big end bolts and caps are designed?
18. Explain the various types of crankshafts.
19. At what angle of the crank, the twisting moment is maximum in the crankshaft?
20. What are the methods and materials used in the manufacture of crankshafts?

Part-B

1. The ball bearings are to be selected for an application in which the radial load is 2000
N during 90 per cent of the time and 8000 N during the remaining 10 per cent. The
shaft is to rotate at 150 r.p.m. Determine the minimum value of the basic dynamic
load rating for 5000 hours of operation with not more than 10 per cent failures.

2. A single row deep groove ball bearing operating at 2000 r.p.m. is acted by a 10 kN
radial load and 8 kN thrust load. The bearing is subjected to a light shock load and the
outer ring is rotating. Determine the rating life of the bearing.

3. A ball bearing subjected to a radial load of 4000 N is expected to have a satisfactory

life of 12 000 hours at 720 r.p.m. with a reliability of 95%. Calculate the dynamic
load carrying capacity of the bearing, so that it can be selected from manufacturer's
catalogue based on 90% reliability. If there are four such bearings each with a
reliability of 95% in a system, what is the reliability of the complete system?

4. A rolling contact bearing is subjected to the following work cycle : (a) Radial load of
6000 N at 150 r.p.m. for 25% of the time; (b) Radial load of 7500 N at 600 r.p.m. for
20% of the time; and (c) Radial load of 2000 N at 300 r.p.m. for 55% of the time. The
inner ring rotates and loads are steady. Select a bearing for an expected average life of
2500 hours.

5. A journal bearing is proposed for a steam engine. The load on the journal is 3 kN,
diameter 50 mm, length 75 mm, speed 1600 r.p.m., diametral clearance 0.001 mm,

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ambient temperature 15.5C. Oil SAE 10 is used and the film temperature is 60C.
Determine the heat generated and heat dissipated. Take absolute viscosity of SAE10
at 60C = 0.014 kg/m-s.

6. A journal bearing is to be designed for a centrifugal pump for the following data :
Load on the journal = 12 kN ; Diameter of the journal = 75 mm ; Speed = 1440 r.p.m ;
Atmospheric temperature of the oil = 16C ; Operating temperature of the oil = 60C;
Absolute viscosity of oil at 60C = 0.023 kg/m-s. Give a systematic design of the
bearing.

7. Design a journal bearing for a centrifugal pump running at 1440 r.p.m. The diameter
of the journal is 100 mm and load on each bearing is 20 kN. The factor ZN/p may be
taken as 28 for centrifugal pump bearings. The bearing is running at 75C temperature
and the atmosphere temperature is 30C. The energy dissipation coefficient is 875
W/m2/C. Take diametral clearance as 0.1 mm.

8. A journal bearing with a diameter of 200 mm and length 150 mm carries a load of 20
kN, when the journal speed is 150 r.p.m. The diametral clearance ratio is 0.0015. If
possible, the bearing is to operate at 35C ambient temperature without external
cooling with a maximum oil temperature of 90C. If external cooling is required, it is
to be as little as possible to minimise the required oil flow rate and heat exchanger
size.
1. What type of oil do you recommend?
2. Will the bearing operate without external cooling?
3. If the bearing operates without external cooling, determine the operating oil
temperature?
4. If the bearing operates with external cooling, determine the amount of oil in kg/min
required to carry away the excess heat generated over heat dissipated, when the oil
temperature rises from 85C to 90C, when passing through the bearing.

9. Determine the dimensions of an I-section connecting rod for a petrol engine from the
following data: Diameter of the piston = 110 mm; Mass of the reciprocating parts = 2
kg; Length of the connecting rod from centre to centre = 325 mm; Stroke length = 150
mm; R.P.M. = 1500 with possible over speed of 2500; Compression ratio = 4: 1;
Maximum explosion pressure = 2.5 N/mm2.

10. A connecting rod is required to be designed for a high speed, four stroke I.C. engine.
The following data are available. Diameter of piston = 88 mm; Mass of reciprocating
parts = 1.6 kg; Length of connecting rod (centre to centre) = 300 mm; Stroke = 125
mm; R.P.M. = 2200 (when developing 50 kW); Possible over speed = 3000 r.p.m.;
Compression ratio = 6.8: 1 (approximately); Probale maximum explosion pressure
(assumed shortly after dead centre, say at about 3) = 3.5 N/mm2. Draw fully
dimensioned drawings of the connecting rod showing the provision for the
lubrication.

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