1. The shaft of an overhang crank subjected to a force P of 1 KN is shown in Fig.

The shaft is made of

plain carbon steel 45C8 and the tensile yield strength is 380 N/mm2The factor of safety is 2.
Determine the diameter of the shaft using the maximum shear stress theory.

2. An offset link subjected to a force of 25 kN is shown in Fig. It is made of grey cast iron FG300 and
the factor of safety is 3. Determine the dimensions of the cross-section of the link.

3. 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.
4. A wall bracket with a rectangular cross-section is shown in Fig. The depth of the cross-section is twice of
the width. The force P acting on the bracket at 60 degree 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.

5. A bracket, made of steel FeE 200 (Syt= 200 N/mm2) and subjected to a force of 5 kN acting at an angle of
30° to the vertical, is shown in Fig. The factor of safety is 4. Determine the dimensions of the cross-section
of the bracket.

6. Figure shows a C-clamp, which carries a load P of 25 kN. The cross-section of the clamp is rectangular
and the ratio of width to thickness (b/t) is 2 : 1. The clamp is made of cast steel of Grade 20-40 (Syt= 400
N/mm2) and the factor of safety is 4. Determine the dimensions of the cross-section of the clamp.
7. Two plates, subjected to a tensile force of 55 kN, are fixed together by means of three rivets as shown in
Fig. The plates and rivets are made of plain carbon steel 10C4 with tensile yield strength of 250 N/mm2.
The yield strength in shear is 50% of the tensile yield strength, and the factor of safety is 2.5. Neglecting
stress concentration, determine (i) the diameter of the rivets; and (ii) the thickness of the plates.
L=200mm

8. A crane hook having an approximate trapezoidal cross-section is shown in Fig.. It is made of plain carbon
steel 45C8 (Syt= 380 N/mm2)and the factor of safety is 3.5. Determine the load carrying capacity of the
hook.

9. A curved link of the mechanism made from a round steel bar is shown in Fig. The material of the link is
plain carbon steel 30C8 (Syt= 400 N/mm2) and the factor of safety is 3.5. Determine the dimensions of the
link.
10. A link of S-shape made of a round steel bar is shown in Figure 1. It is made of plain carbon steel
45C8 (Syt=380 N/mm²) and the factor of safety is 1.5.Calculate the dimensions of the link.

11. A transmission shaft is subjected to Bending moment of 2000 Nm and torsional moment 2500 Nm.
Shaft is made of material with Syt =300 /mm2 ,consider factor of safety 1.5 and determine diameter
of shaft on the basic of Maximum principal stress theory.
12. The layout of a shaft carrying two pulleys 1 and 2, and supported on two bearings A and B is shown
in Fig. The shaft transmits 7.5 kW power at 360 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 2.5:1. The shaft is made of plain carbon steel 40C8 (Syt=
380 N/mm2) and the factor of safety is 3. 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 = 79300 N/mm2.

13. The layout of a transmission shaft carrying two pulleys B and C and 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 coeffi cient 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.

14. The layout of an intermediate shaft of a gear box supporting two spur gears B and C is shown in Fig.
The shaft is mounted on two bearings A and D. The pitch circle diameters of gears B and C are 900
 and 600 mm respectively. The material of the shaft is steel FeE 580 (Sut= 770 and Syt= 580 N/mm2).
The factors kb and kt of ASME code are 1.5 and 2.0 respectively. Determine the shaft diameter using
the ASME code. Assume that the gears are connected to the shaft by means of keys.

15. The standard cross section for flat key, which is fitted on a 50 mm diameter shaft is 15x10 mm
(bxh).The key is transmitting 450 N-m Torque from shaft to hub .The key is made of commercial
steel (Syt=Syc=260 /mm2). Determine length of key, if factor of safety is 1.8
16. A standard splined connection 8 x 52 x 60 mm is used for the gear and shaft assembly of a gearbox.
The splines transmit 25KW power at 360 rpm. Permissible normal pressure on splines is 6.5N/mm2
and coefficient of friction is 0.06. Find:

i. length of the hub of the gear

ii. the force required for shifting the gear
17. Design Muff coupling (with key) to connect 2 steel shafts transmitting 30KW power at 360 rpm. The
shaft and key are made of 30C8,( Syt=Syc=380 /mm2 ).The sleeve is made of gray cast iron with
Sut=Syc=180 /mm2 . Consider Factor of safety for shaft, key and sleeve as 1.6.

Standard Diameter of shaft in mm 25,28,30,32,35,40,45,50

18. A solid circular shaft of diameter d is subjected to a bending moment of M b and a torsional moment
of Mt. Prove that according to the maximum principal stress theory,

19. A solid circular shaft of diameter d is subjected to a bending moment of M b and a torsional moment
of Mt. Prove that according to the maximum Shear stress theory,
20. A rotating shaft, 40 mm in diameter, is made of steel FeE 580 (Syt = 580 N/mm2). It is subjected to a
steady torsional moment of 250 N-m and bending moment of 1250 N-m. Calculate the factor of safety
based on,(i) maximum principal stress theory; and (ii) maximum shear stress theory.

21. A solid circular shaft of diameter d is subjected to a torsional moment of Mt over a length of l. The
permissible angle of twist is q degrees. Prove that the shaft diameter is given by,

22. 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.

23. A single square thread power screw is to raise a load of 50 KN. A screw thread of major diameter of
34 mm and a pitch of 6 mm is used. The coefficient of friction at the thread and collar are 0.15 and
0.1 respectively. If the collar frictional diameter is 100 mm and the screw turns at a speed of 1 rev s-1
find (a) the power input to the screw. (b) combined efficiency of the screw and collar.
24. A triple threaded power screw with ACME threads is used to raise load of 280KN. The nominal
diameter is 100 mm and pitch is 10 mm. The coefficient of friction at screw thread is 0.14 .Neglect
collar friction and calculate
i. Torque required to raise the load
ii. Torque required to lower the load
iii. Efficiency of screw.
25. The lead screw of lathe has single start ISO metric trapezoidal threads of 52 mm nominal diameter
and 8 mm pitch. The screw is required to exert an axial force of 2KN in order to drive tool carriage
during turning operation. The thrust is carried on collar of 100 mm outer diameter and 60 mm inner
diameter. The values of coefficient of friction at screw threads and collar are 0.15 & 0.12
respectively. The lead screw rotates at 30 rpm. Calculate, i) Power required to drive the lead screw ii.
Efficiency of screw
26. A steel plate, 100 mm wide and 8 mm thick, is welded to another steel plate by means of
double parallel fillet welds as shown in Figure The plates are subjected to a static tensile
force of 50 kN. Determine the required length of the welds if the permissible shear stress in
the weld is 100 N/mm2

Figure
27. A rectangular cross-section bar is welded to a support by means of fillet welds as shown in
Figure. Determine the size of the welds, if the permissible shear stress in the weld is limited
to 75 MPa.

28. A steel plate, 80 mm wide and 10 mm thick, is joined to another steel plate by means of a
single transverse and double parallel fillet welds, as shown in Figure. The joint is subjected
to maximum tensile force of 80KN. The permissible tensile and shear stresses for the weld
material and the plates are 100 and 70 N/mm2 respectively. Find the length of each parallel
fillet weld. Assume that the tensile force passes through the centre of gravity of three welds

29. For supporting the travelling crane in a workshop, the brackets are fixed on steel columns as
shown in Figure. The maximum load that comes on the bracket is 12 kN acting vertically at
a distance of 400 mm from the face of the column. The vertical face of the bracket is
secured to a column by four bolts, in two rows (two in each row) at a distance of 50 mm
from the lower edge of the bracket. Determine the size of the bolts if the permissible value
of the shear stress for the
Bolt material is 40 MPa.
 Figure
30. A steel plate subjected to a force of 3 kN and fixed to a vertical channel by means of four
identical bolts is shown in Figure. The bolts are made of plain carbon steel 45C8 (Syt = 380
N/mm2) and the factor of safety is 2. Determine the diameter of the shank.

Figure
31. A steel plate subjected to a force of 5 kN and fixed to a channel by means of three identical
bolts is shown in Figure. The bolts are made from plain carbon steel 40C8 (Syt = 340
N/mm2) and the factor of safety is 2.2. Specify the size of bolts.

Figure
32. A bracket is fastened to the steel structure by means of six identical bolts as shown in
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 the bolts, if the maximum permissible tensile
stress in any bolt is limited to 100 N/mm2.
33. A cast iron bracket fixed to the steel structure is shown in Figure It supports
a load P of 25 kN. There are two bolts at A and two bolts at B. The distances are, l1 = 50
mm l2 = 200 mm & l = 400 mm
Determine the size of the bolts, if maximum permissible tensile stress in the bolt is 50
N/mm2

34. A steel plate subjected to a force of 5 kN and fixed to a channel by means of three identical
bolts is shown in Figure The bolts are made of plain carbon steel 30C8 (Syt = 400 N/mm2)
and the factor of safety is 3. Determine the diameter of the shank

35. A Shaft ( Sut= 550 N/mm2 ) is subjected to completely reversed axial load 110 KN .
Determine the diameter of shaft for infinite life condition.
Consider Ka=0.76, Kb=0.85, Kc=0.86, Kd=1 & Factor of safety 2
36. A Shaft ( Sut= 540 N/mm2 ) is subjected to completely reversed axial load 90 KN .
Determine the diameter of shaft for infinite life condition.
Consider Ka=0.78, Kb=0.85, Kc=0.86, Kd=1 & Factor of safety 1.8
37. A cantilever beam made of cold drawn steel 20C8 (Sut = 540 N/mm2) is subjected to a
completely reversed load of 1000 N as shown in Figure. The notch sensitivity factor q at
the fillet can be taken as 0.85 and the expected reliability is 90%. Determine the fatigue
strength for a life of 10000 cycles.( Ka=0.78,Kb=0.85, Kt=1.35 ,select Kc from book )

Figure
38. A rotating bar made of steel 40C8 (Sut = 590 N/mm2) is subjected to a completely reversed
bending stress. The corrected endurance limit of the bar is 290 N/mm2. Calculate the fatigue
strength of the bar for a life of 80,000 cycles.
39. The work cycle of a mechanical component subjected to completely reversed bending
stresses consists of the following three elements:
(i) ± 380 N/mm2 for 80% of time
(ii) ± 420 N/mm2 for 15% of time
(iii) ± 490 N/mm2 for 5% of time
The material for the component is 50C4 (Sut = 660 N/mm2) and the corrected endurance
limit of the component is 270 N/mm2.
Determine the life of the component.
40. A flat plate subjected to a tensile force of 5 kN is shown in Figure. The plate material is
grey cast iron FG 200 and the factor of safety is 2.5. Determine the thickness of the
plate.(consider only stress concentration factor for calculating high value stresses )
d/w 0.3 0.4 0.5
Kt 2.35 2.25 2.15

41. A Shaft ( Sut= 550 N/mm2 ) is subjected to completely reversed axial load 110 KN .
Determine the diameter of shaft for infinite life condition.
Consider Ka=0.76, Kb=0.85, Kc=0.86, Kd=1 & Factor of safety 2
42. The work cycle of a mechanical component subjected to completely reversed bending
stresses consists of the following three elements:
(i) ± 380 N/mm2 for 80% of time
(ii) ± 420 N/mm2 for 15% of time
(iii) ± 490 N/mm2 for 5% of time
 The material for the component is 50C4 (Sut = 660 N/mm2) and the corrected endurance
limit of the component is 270 N/mm2.
Determine the life of the component.

43. A rotating shaft, subjected to a non rotating force of 5 kN and simply supported between
two bearings A and E is shown in Figure The shaft is machined from plain carbon steel
30C8 (Sut= 500 N/mm2) and the expected reliability is 90%. Determine the life of the
shaft?.
( consider Ka=0.79, Kd=0.64, select kb & kc from Table)

44. A rectangular plate, 15 mm thick, made of a brittle material is shown in Figure

,At which hole value of stress is maximum & Calculate its value ( Calculate high value
stresses by consideration of Kt only)
d/w 0.12 0.2 0.3 0.4
Kt 2.68 2.5 2.35 2.25

45. Write the different derating factors which are considered for approximate estimation of
endurance limit

46. A helical compression spring of a mechanism is subjected to an initial pre-load of 80 N

and the maximum force during the load cycle is 400 N. The wire diameter is 8 mm, while
the spring index is 6. The spring is made of oil hardened and tempered steel wire of
Grade SW (Sut= 1440 N/mm2). Determine the factor of safety against fluctuating
stresses.
47. A safety valve, 40 mm in diameter, is to blow off at a pressure of 1.2 MPa. It is held on
its seat by means of a helical compression spring, with initial compression of 20 mm. The
maximum lift of the valve is 12 mm. The spring index is 6. The spring is made of cold
drawn steel wire with ultimate tensile strength of 1400 N /mm2. The permissible shear
stress can be taken as 50% of this strength. (G= 81 370 N/mm2). Calculate :(i) wire
 diameter; (ii) mean coil diameter; and (iii) number of active coils.
48. A railway wagon of mass 300kN moving with a velocity of 2.5m/sec is brought to rest by
springs of mean diameter 400mm. The maximum deflection of the spring is 250mm. The
spring index can be taken as 6. Find the wire diameter and number of turns. Take
allowable stress = 600MPa and G = 80 GPa.
49. For a helical torsion spring, find the stress and spring gradient using following data:
Diameter of coil – 105 mm
Diameter of wire – 15 mm
Modulus of elasticity – 2.1 X 10^5 N/mm2
Number of active turns – 6
Bending moment – 40.36 kN-mm
50. A safety valve, 40 mm in diameter, is to blow off at a pressure of 1.2 MPa. It is held on
its seat by means of a helical compression spring, with initial compression of 20 mm. The
maximum lift of the valve is 12 mm. The spring index is 6. The spring is made of cold
drawn steel wire with ultimate tensile strength of 1400 N /mm2. The permissible shear
stress can be taken as 50% of this strength. (G= 81 370 N/mm2). Calculate :(i) wire
diameter; (ii) mean coil diameter; and (iii) number of active coils.
51. A railway wagon moving at a velocity of 1.5 m/s is brought to rest by a bumper
consisting of two helical compression springs arranged in parallel. The springs are
compressed by 150 mm in bringing the wagon to rest. The mass of the wagon is 1500 kg.
The spring index can be taken as 6. The springs are made of oil-hardened and tempered
steel wire with ultimate tensile strength of 1250 N/mm2and modulus of rigidity of 81 370
N/mm2. The permissible shear stress for the spring wire can be taken as 50% of the
ultimate tensile strength. Design the springs and calculate: (i) maximum force on each
spring; (ii) wire diameter; (iii) mean coil diameter; and (iv) number of active coils.
52. For a helical torsion spring, find the stresses and no. of turns using following
data:Diameter of coil – 80 mm, Diameter of wire – 10 mm,
Modulus of elasticity – 2.1 X 10^5 N/mm2, Stiffness of spring= 5 N-mm/rad
Bending moment – 35 kN-mm
53. A rotating bar made of steel 45C8 (Sut = 630 N/mm2) is subjected to a completely
reversed bending stress. The corrected endurance limit of the bar is 315 N/mm2.
Calculate the fatigue strength of the bar for a life of 90,000 cycles.
54. A cantilever beam made of cold drawn steel 4OC8 (Sut = 600 N/mm2 and Syt = 380
N/mm2) is shown in Figure. 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.
Assume Ka=0.77,kb=0.85, kc=0.897,kt=1.44
55. Mechanical component subjected to reversed bending moment has
i) life 100000 revolution when x stress applied for 80 % of time
ii) life 40000 revolution when y stress applied for 15 % of time
iii) life 5000 revolution when z stress applied for 5 % of time.
Determine the Total life of component if applied with above case.
56. A plate made of steel 20C8 (Sut = 440 N/mm2) is shown in Figure, It is subjected to a
completely reversed axial load of 30 kN. The notch sensitivity factor q can be taken as
0.8 and the expected reliability is 90%.. Determine the plate thickness for infinite life.
Consider Ka=0.67,Kb=0.85,kc=0.89, kt=2.52

57. A bracket, as shown in Figure carries a load of 10 kN. Find the size of the weld if the
allowable Shear stress is not to exceed 80 MPa.

Figure