Design of Machine ElemenF

B.E/B.TECH. DEGREE EXAMINATION - I'AY/JUNE 2017

Fifth semester
Mechanical Engineering
ME 6503. OCSrcN OF MACHINE ELEMENTS

(common to B.E Automobile EngineerlnglMechanlcal Engineerlng

(Sandwlch)/!ndustrial Englneering/ Mechanlcal and Automatlon
Englneering/Mechatronics Engineering)
(Regulation 2013)

Maxlmum: 100 marks

Tlme: Three hours
Note: Approved Design Data Book is permitted to use in the
examlnatlon'

Any requlred mlssing data can be suitably assumed'

Answer ALL questions

Part A - (10 x 2= 20 marks)

of curved beams?
l. why nonsymmetrical I and T sections are prefened in design

The nonsymmetrical I and T sections are preferred in design

of curved bearft
because of making the pl.ane of loading to lie in a
plane that contains the principal

centroidal axis of cross section of the curved beams'

2. DeJine modulus of resilience and proof resilience'

can be absorbed per
Modulus of resilience is defined as the maximum energy that
be calculated by integrating
unit volume without creating a perrnanent distortion. It can
the stress-sffain curve frotn zero to the elastic limit'
' Proof resilience is defined as the maximum energy that
can be absorbed up to the

elastic limit without creating a permanent distortion'

3. State the reasonslor wlich the couplings are located near the bearings'
to avoid Bending
The couplings are located as near as possible towards bearings
moment due to couPling forces'

4,Listtheadvantagesofcotteriointoverlhreadedioints'
(i) It is quite rigid and can take both tensile and compressive loads.
(ii) It can be easily assembled and dismantled'
(iii) The joint can also be used to connect similar pipes and tubes.
trF'

Solved Anna University euesfion papers

5. Deftne eqaivaled torsional moment ofuW

Equivalent torsional moment may be defined as the torque
which will produce the
same maximum shear stress as producid by the bending
moment and torque acting
separately. 1 : ::

llthy throat ls coisidered while calculaing,stresses infillet welds?.

Throat is considered while calculating stresses in fillet welds

because the failure of
joint often occurs more acrois the throat.

7. Sketch the stresses induced in the cross' section of a helical spring, considering Wahl,s
effect

Sprlng
axts

stress
Direct shear Transverse
shear stress
BPD P Resultant shear stress
rcd' A

Figure QI' Superposition of stresses

What are theforces acting on connecting rotd?

l. The combined effects 'of gaS pressire

Pn
the piston and the inertia of the
reciprocating parts.

2. Inertia of the connecting rod.

J. Friction of the piston rings and of the piston.

4. The friction of the two-end bearings.

lYhat are anti-fricfion beatings?

since the contact between the.bearing elements is rolling, l nr, ,r. has very small
friction and thus, it is also called antifriction bearings.
 Deslgn of tachlne Elenents
r0. Plot thefriuion induced in various bearings bosed on shaft speed.

c
,9,
15
.E
l! bearing

Ballbearing
">
Shafl speed
' Figure QI Comparison offrtcfionlor different bearkgs

PartB-(5xi3=65Marks)
11. (a) Design a reciangular for the foltowing application: A shaft 65 mm diamaer
key
transmits pone? at moximum shear stress of 67 MPa. The shear stress in the kq
shoald nbl qceed 75% of the stress developed in the shaft The key should be u
least 2.5 times strong in crush,ing compared lo shearfailure of the kcy. (13)
Given Data:
Diameter of the shaft, d:65 mm
Shear stress of shaft, Tn,o, : 67 Mpa: 67 N/mm2

shear stress of key, r = 7 5%o of shear stress of sha ft = 0.7 5x67 = 50.2s Mpa
Crushing stress of key , o" = 2.5 times of shear stress of key
:2.5x50.25 = 125.625 Mpa
Tolind:
Design a rectangular key.

@ Solation:
From PSGDB 5.16, for the given shaft diameter of 65 mm
Widthofthekey, b=18mm Ans. !,
Height of the key, h:ll mm Ans. T!
We know that the torsional moment of the shaft

M, =Lrr*4t

*, =#"67x651= 3612.807x l}t N-mm

i
I (i) Checkfor shear strength of key:
h d
I
5.
Mt=tLb
t 2
t
t
t
-
t_t_ M.x2 3612.807x103 x2
= L2?.9 mm= 123 mm
rbd 50,25x18x 65

(ii) Chech for crushing:

F
I
M,= o" L
hd
-x-
22
3612.807 x 103 : 125.625 x Lx
ll 65
-x-
22
L:160.88 mm

For the gafe design of kgy, greater value of key is takep

.', .Length of the kcy, L: 16l mm Ans. t!
Res4lt:
Width of key, b: L8 mm
Height of key, h: ll mm
I-ength of key, L: 16l mm

Or

(b) Design a muff cgupling which is used to connect two steel shalti transmifling 25
k|/ power at 360 rpn, The shafis and key are made of plain carbon steel S0CE (S$
= 400 N/mm2l, The sleeve is made of grey cast iron FG 200 (S*- 200 N/mm2).
' =Sy"
The factor of safuy for the shaf* and key is 4. For sleeve, the factor of safay is 6,
hased on ultimate strength. (r3)

Given data:
Power, P:25 kW - 25 x'103 W
Speed, N:360 rpm

,/ For sleeve: S,,,:200 N/mmz

For shafts and keys: FOS: 4
For sleeve: FOS:6
 @ Solution:

o,=
t,
Permissible yield stress for shafts and key, ,FOS4
-4oo=loo Nlmmz

s*. 400
Permissible crushing stress for shafts and key, o" = *=+=
FOS 4
100 Nlmm2

,n
0'51a00 :50
Permissible shear stress for shafts and key, , = '0'5syr- -
FOS 4
Nlmm2

,r=
Permissible shear stress for sleeve,
ffi=Y: 16.67 Ntmmz

Designing procedure is almost same as Problem 1 in Page 2'87'

IAns:-
Diameter of the shaft, d= 45 mm
Diameter of the sleeve, D ='105 mm
Length of the sleeve, L = 160 mm
Width of the keY, b: 14 mm

Height of the keY,h:9 rum

Length of the keY, l:80 mml
,

12. (a) A hetical compression spring of the qxhaust valve mechanism is initially
comprcssed and
co,mpressed with a preload of 375 N. When the spring is farther
not
the valve is fully opened, the torsional shear stress in the spting wire should
exceed 750 N/mm2. Due to space limitations, the outer diameter of the
spring
weight
shoald not uceed 42 mm. The spting is to be designed fot minimum
(13)
Calculate lhe wire diametet and the mean coil diameter of the spring'

Given data:
Minimum force, Pr,;, =375 N
Shear stress, tmux= 750 MPa=750 Nlmmz
Outer diameter of the spring, Do- 42 mm

Tofind:
(i) Wire diameter
(ii) Mean coil diameter of the spring
(l) Diameter of the spring wire, d:
For minimum weight,

P** = 2P-in. = 2x375 = 750 N

We know that
Do= D*d
= cd+d

= d(C+l)

d= Do = P ...(l)
C+l C+l
8P*9
Allowable shear stress, r,n*. = n
' 750= K.::;rr-
( tz\'
'[ c.t)
c(c+t)2 K, =692,.72 ...(2)
Solving the equation (2) by trial'and error method, it:is found to be
C:8 andK, j t.tS+

d=
42 L = 4.67 mm = S mm Ans. Er
c+r=-8*l
Similarly,meancoildiameter, D=Do-d=42-5=37mm Ans Et

Actual spring ind

cx. c=2=37 =7.4 ,

d 5

wahlstressfactoi, x,= t9--l *0'6-15= 4x7'4-l *o'614 -r.2

4C-4 C 4x7.4-4 7.4

A[owable shear stress, rmox. : I<,g* 9

nxd2

?nrx = ,., *8x750\7 '4 = 678.38 N/mmz

nx5'
It is less ttnn7l}Nlmm2. Hence, the dimensions ar.e safe.
 (b) A punching machine ca.:ries oat punching I0 hotes per minute. Each hote of 36
mm diameter in 16 mm thick plate requires 7 N-m o!'energy/mm' of the sheared
area. The punch has a stroke of 90 mm. Deterntine the power of the motor required
to operate the machine,

Ifthe total fluctuation of speed is not to exceed 2.5% of thc mean speedl determine
lhe mass of the tly .wheel. The mean speed of the /tywheel is t S u/* (l j)

Similar to AU Problem 28 in Page 4.279.

IAns:-
(i) Power of the moror, P:2.11 kll/
(ii) Mass of the flywh eel, m: 175.184 kgl

13, (a) A wall-uone with a pin-joint tie rod is shown in Fig. 13 (a). The qane hook is to
take.a maximum load 35 kN, when the loud is al a tlistunce of 2 m from the walt. The tie
rod and pin are made of steel FeG 250 (Sr: 250 N/mm2) and the factor of safety is 5.
Calculate the diameter of the tie rod and the pin. ( 13)

Pin joint

Tie rod

Figure Q2
Givea dad:
Load, P = 35 fr.rV= 35000 N
Distance from wall, I = 2 m -- 2000 nm
FOS,z=5
Syr = 250 N/mm2

Tofind:
(i) Diameter of tie rod
(ii) Diameter of Pin

@ Solution:

o,=
*' =+=
Permissible tensile shess, 50 Nlmm2

&.
stress,, = 25 Nmm2'
Permissible shear
#=+=
T4king moment about A,

. Px2000= Isin30ox2500

35000x2000 = Ix0'5x2500
I= 56000 N

Figure Q3
T
Permissible stess on tie rod, 6,: il
'4 -d-
 \U= s6000
Ld,
-4
d=37.163 mm
,', Tieroddiam*er, d=38mm Anr. El

Ppnniseible shearshess onpin, ('.' Pin is subjectedto double ffcar)

"=
'4 h
^! _ 56000

zxiai
dp= 37.763 m
,', Pin diameter, do=38 mm TI
Or

(b) A flnl tfrflppd ln lhelorm olalmer S is motu up of i0 mm dimiaa ba4 as shaw

ln Fl* lr@. Dctorrnine the maximum tcnsile sfress and mar;illrlum shcor straes irn
tho lln*r gj)

lkN
Figaru Q4

Similar to Problem I in Page 1.t7.

[Ans:-
l. Maximumtensile stress in the hook : 43.86 N/mmz
2. Maximum shear stress in the hook = 21.93 N/mm2l
14, (a) A bracket is welded to the vertical column by means of two lillet welds as shown in
Fig. 14(a). Determine the size of the welds if the permissible shear s/rass is limited to 70
N/mm2. (r3)

r50r
Figure Q5

Similar to Problem 9 in.Page 3.111.

:.

[Ans:- Size of the weld, & = 2.85 mm say 3 mml

Or

(b) A steel plate is suhjected to aforce of 5 kN andftxed to a channel by means of three

identicat holts as shown in Fig. 14 (b). The bolts are made from 45CB steel (Sy:
380 N/mm2) and thefactor of safety is 3. Specify the size of the bol*. (13)

Figure Q6

Same as Problem 11 in Page 3.41.

 --__l

Deslgn of Machlne'Elements
15' (a) Design aiournal bearing lor a 49.9 mm diameter journal It is ground and
hardened and is rotating ot 1500 rpm in a bearing of diameter and length
both S0 mm.
The inla tumperature of oil 6f C. Determine the maximum radlal load
that the journal
can carry and power loss, @)
Same as AU Problem 13 in page 5.99.

[Hint:- The inlet temperature of oil, f1 is given. So, the operating temperature is
found to be

Lt= 7.02'C
t2- t1 = J.Q2
tz =7.02* tt = 7 .02+65 = 72.02o Q

Or

(b) A ball bearing is subjeaed b a radial load of 10 kN and a thrust of S kN. The inner
ring rotates at 1000 rpm. The average life is to be 5000 hours. What basic load
rating tnust be used to select a bearing for this purpose? Take Fn/c,
=0.s and
assame service factor l.S.
(13)
Given data:

Speed, N:1000 rym

Radial load, F.= 10000 N
Thrust load, ,fl. : 5000.1{
Life, L1:5000 irs
FolC"=9.5
Service factor, ,S = 1.5

@ Solution:

4 = 5ooo =0.5
F, 10000
since $ < 0.7, asingle row deep groove balr
vE'r bearing
vvsr 1116 may
rrrqJ be suitabre. I

F,

From Table 5.3.2 orpSGDB 4.4, corresponding to 4 = 0.5

C,,

e:0.44
Solved An;na tJniversity Question Papers

Since & = 0.5 > e, from Table 5.3.2 or PSGDB 4.4, the radial load factor
F,
X:0.56 and I= I
Equivalent load, P = (X F, + f F,) S
= (0.56 x 10000 + lx 5000) 1.5

P= 15900N
From graph in Figure 5.18 or PSGDB 4.6, corresponding
to l000rpm and 5000&rs

of life, loading ratio,

9 = 6.97
P
C = 6.97 x P = 6'97 x 15900 = I 10823 N
than the required
Since the dynamic load rating of the SKF6208 bearing is more
is suitable' Ans' ir
dynpmic load capacity, the selected bearing

PartG.(1xl5=l5Marks)

t6. (a) A shafi ls supported by two bearings placed 1100 mm aparl A pulley of diameter
drives a pulley
620 mm keyed a|400 mm to the right olthe left hand bearing and this
7s

dlruc.tly below it wtth a maxiuum tenslon

of 2.75 kN' Another pultey of diamet* 400
mu ls placed mm tu the
200 of lhe right hand bearing and is driven with a motor
tefi
putteys is 180" and the
placed horlzontatly to the right The angle of contact of the
diameter of the
qoelftcient of lrtetton befraen the belt and the pulteys is 0'i' Find the
shafi Assuwe Kt= 3, Kt:2,5, Svr= DAMPa and S*t= 300 MPa'
(15)

1100 mm

Figure Q7
 -t
Distance, l=ll00mm
Distance, AC= 400 mm
Distance, AD:90A mm
lY6=2.75 kN:2750 N
Angle of contact, 0 : 180o : n radians
p: 0.3
Kt:3
- K,:2.5
Srt:190 MPa
Su,:300 MPa

@ Solution:
The permissible shear stress of the material considering the effect of keys
is
calculated by

Shear stress based on yield strength, r : 0.3x0.75x190:42.?5 Nlmm2

shear stress based on ultimate strength, r : 0.1gx0.75x300 = 40.5 Nlmmz
Comparing these two stresses, smaller value is taken and used in the calculations.
So, allowable shear stress, t : 40.5 Nlmm2
We know that the belt tension ratio can be written as

rrr-
TT =L- = "*
ZC ZD

1r=!,-
Tr, Tro
=go.3x* =2.566

T;^ =
'c 2.566
=\" =?750 = fi71.707 N
2.566
Similarly, Ttn =2.566Tro

Torque on both pulleys are same. So, it can be written as

(Ttc- Trr) ,r: (Tto- Tro\ ,,
(2750 - 1071.707) 319 = (2.566 TDz- TD) 2OO
T2o= 1661.146 N
 So, Ir, = 1661.146x2.566:4262.5 N

Torque on shaft, M,= (Ttc- Trr) ,,

- 1071.707) 310 = 520271 N-mm
= (2750
Total vertical load on pulley C, Wc : 7rr+ Tz":2750+1071.707 :3[di2l.707 N

Similarly, total horizontal load on pulley D,

Wo: Tro* Trr: 1661.146+4262.5 = 5923.646 N
Now, calculate the bending moments for vertical loads at all points.
:
Let R,ryand Rsyare the reactions at I and.B respectively.

Taking moment about l,

Rwx ll00= Wgx400

Rsyx ll00 = 3821.707x 400

I RtY:1389'712 N
we know that
Rsy* R1Y= 3821.707 N
ReY:3821'707 - Ruv
\, = 3821-707-1389.712=2431.995 N
Bending moments for vertical loads:
BMatl=0
BM at C: Rny x 400: 2431995 x 400 = 972798N-mm

BM D= Rsyx200=
at 1389.712 x 200 = 277942.4N-mm

BM at D=0
Now, calculate the bending moments for horizontal loads at all points.
Let Ren and Rrr are the reactions at A arid B respectively.

Taking tnoment about .,4,

RsH x 1100= Wpx4O0

.Rar x I100 = 5923.646x 400
' RBu:4846'62 N
We know that

Ru;+ R,tn= 5923.646 N

Rtn= 5923.646 - Rrn
:--\
r\\
 = 5923.646- 4846.62

(a) ritat load dia{ram

3821i.707 N i

Cr

(b) veiical load d{ram

(f) Resultant BMD

Figure QB
loads :
B ending moments for horizontal
BM at.'4 = 0
N'mm
- 5923'646x500 = 430810
BM at C = 4846'62x 700

BM at D: 4846.62x'200 =
969?24N-'mm :

' BM at D = o
at A arrd B are'zero.' fn'- -- the resultant
rd Put
Resultant bending moments -:tt :
vertical andhorizontal load'
BM at C and D'due to cornbined
 Resultant BM = ,tuj +u'z,

Resultant BM at C= 9727982 +4308102 =1063921 N.nCIt

Resultant BM at D = 277942.42 + 9693242 = I 0083t5 /V-rnnt

The resultant bending moment diagram is shown in Figure Q8 (f)

From above results, it is found that the resultant BM is rnsrimm at C and
hence, the calculation for diameter of the shaft is made for this BM.
Mt = 1063923 N'mm
Equivalent twisting moment,

Mb= KoM)' +1.X,tr,t,12

:3446614 N-mm

Also, we know that

tu!.
', -L*rxdl
16

346614=Lx40.5xd!
l6
d = 75.69 mnt
The nearest standard dianreter of the shaft, d = E0 mm Anc.

\
(b) A solid circubr fiaft of dtameter 45 mm is loadid.,by ben(ing morncnt 650 Nm,
btqae 900 Nm aad an oxial tenslle lorce of 30 kN. The shaft moteriol is duaile
with yicld strength of 280 MPu Determine the lactor of salety according to
Maximum principtlstress, Tresca and Vonnisses theoties offailure. (15)

Given dala:
d:45 mrn
. Mr,= 650 Nn = 650000 N-mm
M,=90Q Nra = 900000 N'mm
f': 30 &N= 30000 N
'oy= 280 MPa=280 N/mmz
I

Totind:
Factors of safety, n

@ Soladont

Axial tensile stress, oo-

a4F
- ax3oo9o=
ttx45'
r8.E63 N/mm2

Bending stress due b Mt, oo= = =72.675 N/mm2

ff #
shear stress due to M,,, = = 50.3N/mm2
#= #
Combined stress, <r: 616a 616= 18.863 +72.6'15..=91.52 N/mmz

Maximum principat stress, o, =

|[o*1/EI7]
=j(u.sz*,ffiP)
= 113.76 N/mmz

Minimum pnncipal stress, * : *[t-6IF]

=)(ryaffi|
=-22.24 N/mm2

(i) Using mafimum principol th:cory: !

ov 290
Factor ofsafety, fl=-L=-=2.461 Ans. !t
, or 113.76
(i0 Using maximum shear stress theory:

According to this theory, 6r

o'
- oz =

I t3.76-(-22.24)- 280.
^n
n=2.M Ans.
Solved Anna lJniversity buestion Papers
(rlt) UsinS distoqtlon enetg, theory or Von Mises theory:
' According to this theory,

(o \'
gr2 * orr r - 61d2-61d3-6rdr =
612
t t'J
As 01= 0, the above eqiration redu-ces to

o 2+ oz2 _ 616:
[+)'
t8.162 + Q2.2412- [l13.76 x (-22.24)]: (#l
r5e6s.e8:(#),
n:2.22 Ans. =,
. From above results, Vori Mises theory is less conservative than Tresca but it is more
yields
conservbtive than maximum principal.stress theory. Hence, Von Mises theory
higher factor of safetv

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