INSTITUTE OF AERONAUTICAL ENGINEERING

(Autonomous)
Dundigal, Hyderabad -500 043

MECHANICAL ENGINEERING

TUTORIAL QUESTION BANK

Course Name : DESIGN OF MACHINE MEMBERS-I

Course Code : A50316
Class : III B. Tech I Semester
Branch : ME
Year : 2017 – 2018
Course Coordinator : Mr. G.V. R. Seshagiri Rao, Associate Professor
Mr. G.V. R. Seshagiri Rao, Associate Professor, Mr. V. K.V.S. Krishnam Raju,
Course Faculty :
Associate Professor

OBJECTIVES

To meet the challenge of ensuring excellence in engineering education, the issue of quality needs to be
addressed, debated and taken forward in a systematic manner. Accreditation is the principal means of quality
assurance in higher education. The major emphasis of accreditation process is to measure the outcomes of the
program that is being accredited.

In line with this, Faculty of Institute of Aeronautical Engineering, Hyderabad has taken a lead in incorporating
philosophy of outcome based education in the process of problem solving and career development. So, all
students of the institute should understand the depth and approach of course to be taught through this question
bank, which will enhance learner‟s learning process.

S No QUESTION Blooms Course

taxonomy Outcomes
level
UNIT – I
INTRODUCTION AND FATIGUE LOADING
Part - A (Short Answer Questions)
1 List out various factors to be considered while designing a machine element Remember 1
2 Illustrate the properties of non-metals Understand 1
3 State the applications of non-metals in design Understand 1
4 Write the difference between ductile and brittle Understand 1
5 Define stiffness for axial loaded member Understand 1
6 Write about factor of safety under static loading and fluctuating loads Remember 1
7 Write short notes on design procedure based on strength and rigidity Remember 1
8 Define fatigue Remember 1
9 Define fatigue stress concentration factor Remember 1
10 Define is stress concentration? Apply 1
11 Define is Theoretical stress concentration factor Understand 1
12 What is notch sensitivity? Remember 1
13 Define factor of safety for fatigue loading Remember 1
14 Define completely reversed loading Remember 1
15 Define alternating loading Remember 1
 16 Define repeated loading Understand 1
17 Write equation for mean average stress Understand 1
18 Write equation for variable stress Understand 1
19 Define stress ratio Apply 1
20 Explain manufacturing consideration in design Remember 1
Part - B (Long Answer Questions)
1 a. Define “Machine Design”. Understand 1
b. i) A symmetrical link shown in Fig. Carries a tensile force of 10kN.
The ratio b/t =4 and material used is 30C8 with Sy=350 MPa. Find b
and t with F.S=4. If shape of the link is modified as in Fig. E-3.4
ii) Determine increase in the width b and thickness„t‟.

2 a. What is factor of safety? Why is it necessary? Why a very small or a Analyzing 1

very large factor of safety should not be used?
b. A cylindrical boiler as shown in Fig. E-3.6, two metre diameter made
of sheet metal 20n mm thick, is subjected to an internal pressure of 1.5
MPa. Find the factor of safety by using different theories of failure. S y=
350 MPa. µ = 0.25.

3 a. Define simple stress and give few examples of machine components Understand 1a
subjected to simple stress.
b. Determine the diameter of a ductile steel bar subjected to an axial
tensile load of 40kN and a torsional moment of 16 x 10 5 N.mm. Use
factor of safety of 1.5, E=2 x 105 MPa and Sy = 210 MPa.
4 a. Define failure. What are the possible modes of failure? Apply 1a
b. A shaft is designed based on maximum energy of distortion as the
criteria of failure and factor of safety of 2. The material used is 30C8
steel with Sy = 310 MPa. The shaft is subjected to an axial load of 40
kN. Determine the maximum torque that can be applied to the shaft
before yielding. Diameter of shaft is 20 mm.
5 a. Design of a part subjected to bending moment is done on the basis of Analyzing 1a
safe tensile stress. Why?
b. A cylindrical shaft of outer diameter double the inner diameter is
subjected to a bending moment of 15000 N. m and torque of 25000
N.m. Find the dimensions of shaft with F. S of 2.
6 a. “Maximum shear stress theory is more reliable as compared to Understand 1
maximum principal stress theory under the state of biaxial stresses of
opposite nature.” Explain.
b. A hub is press fitted on a shaft. An element in the hub is subjected to a
radial compressive stress (Pressure) of 50 MPa and hoop stress of 75
MPa. Find the factor of safety if
(i) hub is made of 30C8 steel with Sy = 350 MPa. Using maximum shear
stress theory
(ii) if the hub is made of C.I with Sut = 200 MPa, Suc = 700 MPa.
 7 a. Explain which three theories of failure are applicable to ductile Evaluate 1
materials.
b. Prove that for maximum shear stress theory Sys = 0.5 Sy for pure shear
and Sys = 0.577 Sy for pure shear with energy of distortion theory.
8 The non-rotating shaft shown in Fig. E-4.7 is subjected to a load P varying Apply 4
from 4000 N to 12000 N. The material 30C8 steel has S u = 600 MPa and Se
= 300 MPa. Ka = 0.8, Kb = 0.85 and Kc = 0.9.
Find the dimension D for a factor of safety of 3.5, and q = 0.9.

9 The endurance strength for a part is 280 MPa while Su = 630 MPa. It is Apply 4
subjected to a loading as follows

σm1 = 315 MPa and σv1 = 96 MPa for 80% of time

σm2 = 245 MPa and σv2 = 145 MPa for 20% of time

Find the expected life in number of cycles of reversals. Assume Kt = 1.5.

10 A shaft is subjected to a torque varying between 5000 N.m to 10000 N.m. Understand 4
The stress concentration factor due to the keyway is 2.5. S u = 500 MPa, Se =
0.5 Su, Sy = 300 MPa, endurance correction factor = 0.6, size correction
factor = 0.8 and surface correction factor = 0.82. Find the diameter of th
shaft using F. S = 2
Part - C (Problem Solving and Critical Thinking Questions)
1 A torque varying from 25kN. M to 75 kN. M is applied at the end of the Apply 4
shaft. Fillet radius
d
r , factor of safety = 1.6, material is 40 MN 2512 with S y =
8
350 MPa. Se = 250 MPa, Ka = 0.85, Kb = 0.82, Kc = 0.6, SCF due to
keyway = 1.6 q = 0.9.

2 a. Define endurance test and endurance limit. Understand 4

b. A Shaft of diameter d is subjected to a torque varying between 100 N.m
to 500 N.m . Kr due to keyway is 1.5. F.S = 2, Sy = 300 MPa, Se = 200
MPa. Correction factor for torsion = 0.6. Surface finish factor = 0.85
and size factor = 0.82. Find the value of d.
3 a. What is stress concentration? How does it affect the fatigue strength? Evaluate 1
b. What are the different methods to reduce stress concentration?
4 a. Draw and explain the S-N diagram. Understand 2
b. A uniform bar having a machined surface is subjected to an axial load
varying from 400kN to 150 kN. The material of the bar has S u = 630
MPa. Kc = 0.7 and Kt = 1.42. Find the diameter d of the rod using F.S =
1.5.
 5 a. Differentiate between boiler and structural joints. Apply 1
b. Two plates of 16mm thick are joint by double riveted lap joint pitch of
each of row of rivets is 90mm. rivets are 25mm in diameter permissible
stresses are 140 MPa in tension. 80 MPa in shear & 160 MPa in
crushing. Find efficiency of joint.
UNIT - II
DESIGN OF FASTENERS AND WELDED JOINTS
Part – A (Short Answer Questions)
1 Explain the term riveted joint Remember 2
2 Explain is caulking and why is it necessary Remember 2
3 Explain diagonal pitch in riveted joint Understand 2
4 Explain margin in riveted joint Remember 2
5 Explain pitch in riveted joint Remember 2
6 Explain back pitch in riveted joint Remember 2
7 Explain uniform strength of riveted joint Apply 2
8 Define term welding joint Analyze 2
9 Difference between welding joint and riveted joint Remember 2
10 Explain the advantages of welded joint Remember 2
11 Explain the advantage of riveted joint Remember 2
12 Explain the disadvantage of welded joint Remember 2
13 Explain the disadvantage of riveted joint Remember 2
14 Write the methods to make bolts and screws Remember 2
15 Explain about gasket Remember 2
16 Classify the types of riveted joints Remember 2
17 Classify the types of rivets Remember 2
18 Explain about Fullering Remember 2
19 Define fillet welds Remember 2
20 Why connected rod bolts are tightened with initial tension greater that Remember 2
external load
Part - B (Long Answer Questions)
1 Determine the size of the rivets required for the bracket shown in Fig.Take Evaluate 2
the permissible shear stress for the rivet material as 100MPa.

2 a. Sketch any three basic types of welded joints. Apply 2

b. Figure shows an eccentrically loaded welded joint. Determine the fillet
veld size. Allowable shear stress in the weld is 80 MPa.
 3 a. Differentiate between (i) lap joint and butt joint, and Understand 2
(ii) chain riveting and zig-zag riveting.
b. Double riveted lap joint is made between 15mm thick plates. Rivate
diameter and pitch are 25mm and 75mm respectively. If UTS are 400
MPa intention 320 MPa in shear & 630 MPa in crushing find minimum
force for pitch which will replace the joint. If above joint is subjected to
load such that factor of safety is 4 find out actual stresses developed in
the plate and rivets.
4 a. What are V threads used for fasteners? Understand
b. What are the different series of threads and their applications?
5 a. Compare the welded joint with riveted joint? Evaluate 3
b. Find the size of the weld in Fig. if the permissible shear stress is 80 MPa
and the load acting on the connection P=60kN.

6 A cast iron cylinder head is fastened to a cylinder of bore 500mm with 8 stud Apply 2
bolts. The maximum pressure inside the cylinder is 2 MPa. The stiffness of
park kp=3kb. What should be the initial lightening load so that the joint is
leakproof at maximum pressure?
7 a. Derive the expression for the maximum stress induced in weld subjected Apply 3
to torsional loading.
b. A cylindrical beam is attached to support by weld as shown in Fig. and
is subjected to a bending moment M. Find the maximum stress induced
in the weld.

8 Fig. shows a plate bracket welded to a steel column loaded eccentrically. Apply 3
assuming that the size of weld 6 x 6 mm, determine the maximum stress
induced in the weld.

9 a. Differentiate between a stud, a bolt and a nut. Understand 2

b. The cylinder head of a steam engine with 250mm bore is fastened by
eight stud bolts made of 30C8 Steel. Maximum pressure inside the
cylinder is 1 MPa. Determine the size of bolts and the approximate
tightening stress and torque. Take 20% overload. Assume S y=300 MPa
for bolt material.
10 a. What are the different types of the stresses induced in bolts? Explain the Understand 3
procedure of designing a bolt subjected to direct tensile load.
b. A bracket is fitted to the channel with 4 bolts. The dimension
a=b=150mm distance of load from the C.G of the bolt arrangement is
300mm. Find the diameter of the bolts.
Part - C (Problem Solving and Critical Thinking Questions)
 1 A bracket is fitted to a vertical channel with 5 bolts, three at the top arid two Understand 2
at the bottom with all the bolts equally spaced. The value of P=20 kN,
e=200mm, l1=50mm and l2=250mm. Find the diameter of the bolt.
2 a. What is meant by a bolt of uniform strength? Evaluate 2
b. A steam engine cylinder of 300mm effective diameter is subjected to a
steam pressure of 1.5 N/mm2. The cylinder head is connected by means
of 8 bolts having yield strength of 320 MPa, and endurance limit of 240
MPa. The bolts are tightened with an initial preload of 1.5 times that of
steam load. A soft copper gasket is used to make the joint leak proof.
Assuming a fatigue stress concentration factor of 1.4, and factor of
safety of 2; determine the size of the bolts required.
UNIT-III
KEYS, COTTERS AND KNUCKLE JOINTS
Part - A (Short Answer Questions)
1 Define what is a key where it is used Remember 3
2 Explain saddle key Understand 3
3 Explain sunk key Understand 3
4 Explain flat key Understand 3
5 Explain feather key Understand 3
6 Explain Kennedy key Understand 3
7 Explain the effect of key way on strength of shaft Remember 3
8 Explain what do u mean by cotter Remember 3
9 Which material is generally used for cotter Understand 3
10 Why taper is given to the cotter Remember 3
11 Explain the purpose of Gib in cotter joint Understand 3
12 Write the applications of cotter joints Understand 3
13 Explain how slipping of cotter is avoided Remember 3
14 Explain types of stresses are introduced in a key Understand 3
15 Write the advantages of key Remember 3
16 Write the demerits of key Remember 3
17 Explain round key Remember 3
18 Write the applications of key Remember 3
19 Explain Gibhead key Remember 3
20 Explain about woodruff key Remember 3
Part – B (Long Answer Questions)
1 Design a spigot and socket joint to connect two rods of 30 C8 steel to carry Analyze 1
an axial tensile and compressive load of 10 kN.

2a. Design a knuckle joint to connect two tension rods subjected to an axial load Apply 1
of 15 kN. Use 30C8 steel material for all the components.
The four components of a joint are (i) double eye end, (ii) single eye end,
(iii) pin and (iv) split pin.
 3b. a. Classify the keys and state their applications. Understand 2
c. b. Figure shows the dimensions of a woodruff key. The key is mounted on a
30mm diameter shaft, transmitting 5kW power at 240 r.p.m. the yield
strength in shear for the key material is 280 MPa, and in crushing, 460 MPa.
Calculate the factor of safety used in the design, considering both crushing,
and shearing of the key.

4d. a. Where and why the woodruff key is used? Analysis 3

e. b. A 30 kW power is transmitted at 240 r.p.m, from 40 mm diameter shaft,
by means of two kennedy keys of 12 x 12 mm cross-section. Determine the
length of the keys. For the keys, take permissible shear stress as 60 MPa, and
crushing stress as 90 MPa.
5f. Design a cotter joint to connect two mild steel rods for a pull of 30 kN. The Remember 3
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.
6g. Two rod ends of a pump are joined by means of a cotter and spigot and Apply 1
socket at the ends. Design the joint for an axial load of 100 KN which
alternately changes from tensile to compressive. The allowable stresses for
the material used are 50 MPa in tension, 40 MPa in shear and 100 MPa in
crushing.
7h. Design a cotter joint to connect a piston rod to the crosshead. The maximum Apply 1
steam pressure on the piston rod is 35 KN. Assuming that all the parts are
made of the same material having the following permissible stresses:
i. σ1=50 MPa; τ = 60 MPa and σc=90 MPa
8j. Design a knuckle joint to connect two mild steel bars under a tensile load of Apply 1
25 kN. The allowable stresses are 65 MPa in tension, 50 MPa in shear and
83 MPa in crushing.
9k. A knuckle joint is required to withstand a tensile load of 25 kN. Design the Apply 1
joint if the permissible stresses are:
l. σ1=56 MPa; τ = 40 MPa and σc=70 MPa
10m. A gear is mounted centrally on a shaft of 0.25m length, between the Analysis 3
supports. The pitch circle diameter of the gear is 0.15m. The gear transmits
10kW power at 240 r.p.m. assuming suitable stresses for the materials,
determine
n. i. shaft diameter,
o. ii. Key dimensions and
p. iii. Minimum width of the gear.
UNIT-IV
DESIGN OF SHAFTS AND SHAFTS COUPLINGS
Part – A (Short Answer Questions)
1 Define shaft Remember 4
2 Write the application of shafts Remember 4
3 Explain the materials used for making shafts Remember 4
4 Define hollow shaft s Remember 4
5 Define equivalent bending moment Remember 4
6 Define equivalent twisting moment Remember 4
7 Define coupling Remember 4
8 Explain classification coupling Remember 4
9 Explain functions of coupling Remember 4
10 Write the applications of coupling Remember 4
11 Explain about universal coupling Remember 4
 12 Explain about bushed pin flexible coupling Remember 4
13 Write merits and demerits bushed pin flexible coupling Apply 4
14 Define clutch Apply 4
15 Define rigid coupling Apply 4
16 Write the difference between shaft and axle Apply 4
17 Define torsional rigidity Apply 4
18 Define lateral rigidity Apply 4
19 Explain causes for failure of shaft Apply 4
20 Define transmission types of shafts Analyze 4
Part – B (Long Answer Questions)
1 For the shaft shown in Fig. the ratio of belt tension for either belt is 3:1. The Apply 3,4
maximum tension in the belt is 3000 N. Sut = 650 MPa, Sy = 400 MPa for the
shaft material. Km = 1.5, Kt = 1.2. Determine the shaft diameter and angle of
twist when the pulleys are keyed to the shaft.
2 A 600 mm diameter pulley driven by a horizontal belt transmits power to a Analyze 3,4
200 mm diameter pinion. The pulley has a mass of 90 kg, Km = 2, Kt = 1.5
and   40 MPa. Find the diameter of the shaft.
3 Design a line shaft transmitting power to two machine tools. The power Analyze 4
received by the shaft is 30 kW at 300 r.p.m. The power absorbed by pulley
PI is 12 kW and the remaining power is absorbed by pulley P2. The diameter
of pulley P1 is 300 mm and its mass is 40 kg. The diameter and mass of
pulley P2 are 600 mm and 75 kg respectively. Assume the belt tension ratio
of 2 for both pulleys and the shaft material is 30C8 steel with K m = 2 and Kt
= 1.5. Draw the b.m and torque diagrams, assuming maximum shear stress
theory.

4 Design a rigid muff coupling. Use C.I for the muff. The power transmitted is Apply 4
25kW at 300 r.p.m. Sut = 200 MPa, F.S = 6, use 30C8 steel for the shaft
consider Sy = 330 MPa and F.S = 4.

5 For the connection of above shafts if the protected type of flange coupling is Apply 4
used, find the dimensions of flanges and bolts.
6 Design a bushed pin type of flexible coupling to connect the motor shaft and Understand 4
pump shaft of 50 mm and 40 mm diameter respectively when 15kW power
is to be transmitted at 1200 r.p.m, the permissible bearing pressure for pin is
0.3 MPa.
 7 Design a split muff coupling to transmit a power of 25 kW at 300 r.p.m. Use Apply 4
the same materials as in example

8 A shaft is subjected to loads as shown in Fig. Gear C is connected to the Analyze 4

other gear such that 50 kW is transmitted at 100 r.p.m. The pressure angle of
the involute gear teeth is 200. The ratio of belt tensions for pulley A is 2:1,
the diameter of pulley being 750 mm. the sprocket B is 500 mm diameter
with negligible tension in the chain on the slack side. The diameter of gear C
is 300mm. The power transmitted by chain drive is 20 kW, the remaining
being transmitted by the belt drive. Find diameter of the shaft if F.S=3, Km =
1.5, Kt = 1.2 and Sy = 350 MPa for shaft material.

9 Calculate the diameter of the solid circular shaft shown in Fig. to transmit 45 Apply 4
KW at 1000 rpm the pressure angle of the involute bevel and spur gears is
200. Diameter of bevel gear C=500mm and the diameter of spur pinion
D=300mm. Assume complete power being transmitted and safe shear stress
for shaft equal to 60 MPa.
10 An electric motor drives a machine through a pair of spur gears. The pinion Apply 4
is mounted on motor shaft and overhangs by 200 mm from the nearest
bearing. The pinion has 20 teeth of 10 mm module and 20 0 involute profile.
Design the motor shaft to transmit 15 kW at 1200 rpm. Use safe shear stress
value of 400 MPa, Km = 1.2 and Kt =1.
Part - C (Problem Solving and Critical Thinking Questions)
1a. A shaft subjected to a b.m due to the weight of the pulley equal to 2000N Apply 4
and a non-rotating load of 800 N acting vertically downwards rotates at a
speed of 1400 r.p.m. The distance between the bearings is 1 m. The external
load and the load due to pulley act at a distance of 300 mm from L.H.
bearing. The material of the shaft has Sy = 300 MPa and Se = 200 MPa.
Using F.S = 2.5, find the diameter of the shaft if Kt due to keyway is 1.3.

UNIT-V
MECHANICAL SPRINGS
Part - A (Short Answer Questions)
1 Define spring Evaluate 5
2 Explain functions of spring Remember 5
 3 Explain why the circular cross section used mostly for spring Remember 5
4 Define flat springs Remember 5
5 Define spiral springs Remember 5
6 Define helical springs Understand 5
7 Define spring index Remember 5
8 Define free length Remember 5
9 Define solid length Understand 5
10 Define active number coils Remember 5
11 Define the phenomenon of surging in springs Remember 5
12 Explain about ground ends Understand 5
13 Explain about square ends Remember 5
14 Define methods to avoid surge in springs Understand 5
15 Define leaf springs Remember 5
16 Explain why leaf springs are made in layers instead of single plate Remember 5
17 Define helical torsion spring Remember 5
18 Explain spiral torsion spring Remember 5
19 Define Wahls factor Remember 5
20 Define spring rate Remember 5
Part - B (Long Answer Questions)
1 A railway wagon of mass 20000 kg moving with a velocity of 2 m/s is Understand 5
brought to rest by two buffers of a spring of diameter 300 mm. The
maximum deflection of the spring is 200 mm. permissible shear stress is 600
MPa. Find the dimensions of each spring.
2 Design a close coiled helical spring subjected to a tensile load of magnitude Apply 5
varying from 2500 N to 3000 N. The axial deflection of spring for this range
of load is 6.5 mm. Design the spring, talking the spring index as 6 and the
safe shear stress for material of the spring equal to 465 MPa.
3 A load of 5 kN is dropped from a height of 50 mm axially on the spring of a Analyze 5
wire of diameter 12 mm, spring index equal to 6 and the number of active
coils as 8. Find the stress induced in the spring
4 A helical spring is subjected to a continuously varying load. A number 7 oil Analysis 5
tempered wire is used with the mean diameter of the coil as 26 mm. The
maximum and minimum force acting on the spring is 400 N and 260 N
respectively and deflection during this variation is 8mm. Find the factor of
safety and number of active turns. For No. 7 wire oil tempered S u = 1400
MPa, Sys =0.4 Su, Ses=0.23Su and d=4.5mm.
5 A helical compression spring carries a fluctuating load varying from 428 N Apply 5
to 642 N. The spring index is 6 and factor of safety is 1.5. S ys = 648 MPa,
Ses = 375 MPa. Calculate the spring wire diameter and the number of
effective turns if deflection due to variation in load is 4mm.
6 Design the cantilever leaf spring to absorb 600 N.m energy without Apply 5
exceeding a deflection of 150 mm and permissible stress of 800 MPa. The
effective length of the spring is 500 mm. E=0.2 x 10 6 MPa
7 A Close coiled helical compression spring is used in the spring loaded safety Apply 5
valve of 80mm diameter. The blow off pressure is 1.4 MPa and maximum
lift is 18 mm. Material of the spring is oil quenched steel with a safe shear
stress of 500 MPa. Spring index is 6. The normal pressure inside the boiler is
1.00 MPa and G=0.84 x 105 MPa. Design the spring
8 Design a tension spring for a spring balance when the maximum load to be Apply 5
weighed is 1000N. Length of the scale is 100mm and the spring index is 5.
The material has the maximum permissible shear stress of 600 MPa and
G=0.8 x 105 MPa.
 9 The blow off pressure for a safety valve is 1.2 MPa with the maximum lift Evaluate 5
of the valve as 10 mm. The valve of diameter 69 mm is loaded with a spring
of spring index 5.5 and an initial compression of 40 mm. Maximum
permissible shear stress for the spring material is 500 MPa, G=0.8 x 10 5
MPa. Design the spring
10 A helical compression spring is subjected to a load varying between 800 and Apply 5
1500 N. The material used is oil tempered cold drawn wire having S ys = 700
MPa and Ses = 356 MPa. Find the diameter of the wire and the number of
coils if C=5 and N=2.5
11 A close coiled helical compression spring has a mean coil diameter of 60 Evaluate 3
mm and the diameter of the wire is 10mm. Number of active and inactive
coil turns is 11 and 2 respectively. Free length of the spring is 210mm.
Decide the maximum load that can be applied on the spring if the minimum
load is one third of the maximum load. Use F.S = 1.5, S ys =700 MPa and Ses
= 1360 MPa.

Prepared By: Mr. V. K.V.S. Krishnam Raju, Associate Professor

Mr G.V. R. Seshagiri Rao, Associate Professor HOD, MECHANICAL ENGINEERING