2020

MPROVEMENT

Detailed Explanations of
Objective & Conventional Questions

Mechanical Engineering
Machine Design
 1 Design for Static Loading

1. (a)

2. (a)

3. (a)

4. (d)

5. (b)

6. (b)

7. (b)

8. (d)

9. (b)

10. (c)

11. (a)

12. (a)

13. (a)

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 Rank Improvement Workbook 3

Solution : 14
Pitch of the threads (p) = 2.4 mm
Angle through which nut is tightened = 45°
2.4 × 45°
∴ Axial movement of nut = = 0.3 mm
360°
Asteel = 0.785 × 182 = 254.47 mm2
Acopper = 0.785(302 – 202) = 392.70 mm2
The stress developed in bolt = + σb (tensile)
stress developed in tube = – σt (compressive)
Due to tightening of the nut, the bolt is extended and tube is contracted
σ b A b – σt A t = 0
σb × 254.47 = σt × 392.70
or σb = 1.543 σt
σb σ × 500 σb
Extension in bolt = ×L = b =
Es 2 × 106 400
σt σ × 500 σ
Contraction in tube = ×L = 1 = t
Ec 1× 10 6
200
Axial movement of nut = extension nut + contraction in tube
σb σ
or 0.3 = + t
400 200
or σb+ 2σt = 120
or (1.543 + 2)σt = 120
120
σt = = 33.87 N/mm2 (compressive)
3.543
σb = 1.543 × 33.87 = 52.26 N/mm2 (tensile)

Solution : 15
Given: P = 2.5 kN, Sut = 300 N/mm2, (fs) = 3
Step I: Calculation of permissible stress
Sut 300
σmax = = = 100 N/mm2
(fs) 3
Step II: Bending stress at fillet section
Due to symmetry, the reaction at each bearing is 1250 N. The stresses are critical at two sections: (i) at the
centre of span and (ii) at the fillet. At the fillet section,
32Mb 32(1250 × 350)
σo = = N/mm2
πd 3 πd 3
K t = 1.61
⎛ 7174704.8 ⎞
∴ σmax = Kt σo = 1.61⎡ 32(1250 × 350) ⎤ = ⎜ ⎟⎠ N/mm
2
⎢ πd 3 ⎥ ⎝ d 3
⎣ ⎦
Step III: Bending stress at centre of the span

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 • Machine Design
4 Mechanical Engineering

32Mb 32(1250 × 500) ⎛ 4783018.6 ⎞ 2

σo = = = ⎜ ⎟ N/mm
πd 3
π(1.1d ) 3 ⎝ d3 ⎠
Step IV
IV:: Diameter of beam
From (i) and (ii), it is seen that the stress is maximum at the fillet section. Equating it with permissible
stress,
⎛ 7174704.8 ⎞
⎜ ⎟ = 100; d = 41.55 mm
⎝ d3 ⎠

Solution : 16
Given: Shaft Power = 2 kW at N = 750 rpm, Kb = 1.5, Kt = 1.0, τ(allow) = 65 MPa
Let the tensions in belt of pulley B be T1, T2.
Then tensions in belt of pulley D are T3, T4. (T1 + T2) (T3 + T4 )
Mt = torque transmitted
A
B C D
2 πNMt
P = RC
60 RA

120 180 60
60 × 2 × 103
Mt = = 25.47 N-m
2π(750)
Also, Mt = (T1 – T2)RB = (T3 – T4)RD
25.47 × 103 = (T1 – T2) × 150
T1 T
And = 3 = 3 (Given) (i)
T2 T4
25.47 × 103 = (2T2) × 150
T2 = 84.92 N
from (i) we get T1 = 254.77 N
T = (T3 – T4) × RD
25.47 × 103 = (2T4) × 75
T4 = 169.8 N
from (i) we get T3 = 509.4 N
RA and RC be the reaction forces,
RA + RC = (T1 + T2) + (T3 + T4) = 1018.89 N ...(ii)
Taking moment about point A
(T1 + T2) × 120 + (T3 + T4) × 360 = RC × 300
40762.8 + 244512 = RC × 300
RC = 950.916 N
from (ii) we get RA = 67.974 N
Bending moment at B MB = RA × 120 = 8156.88 N-mm
MC = (T3 + T4) × 60 = 40752 N-mm
Maximum Bending moment will be at ‘C ’ .
Let Te = Equivalent torque = (K bMb )2 + (K t Mt )2

= (1.5 × 40752)2 + (1× 25.47 × 103)2 = 66,222 N-mm

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 Rank Improvement Workbook 5

16Te
Also, τ =
πd 3
16 × 66,222
65 = ⇒ d = 17.315 mm or
πd 3
Diameter of shaft = 20 mm

Solution : 17
b = 120 mm, t = ?, Pmax = 250 kN, Pmin = 100 kN,
σe = 225 MPa, σy = 300 MPa, FOS(N) = 1.5
Let t = thickness of the plate in mm
Area, A = bt = 120 t mm2
Pmax + Pmin 250 + 100
Pmean = = = 175 kN
2 2
Pmax − Pmin 250 − 100
Pvariable = = = 75 kN
2 2
Pm 175 × 103 1458.33
σmean = = = N/mm2
A 120t t
Pv 75 × 103 625
σvariable = = = N/mm2
A 120t t
According to soderberg’s formula:
1 σm σv
= +
N σy σe

1 1458.33 625
= +
1.5 300 t 225 t
⎛ 1458.33 625 ⎞
or t = 1.5 ⎜ + = 11.458 mm
⎝ 300 225 ⎠⎟
or thickness, t = 11.5 mm

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 2 Design Against
Fluctuating Loading

1. (a) 11 (a)

2. (a) 12 (b)

3. (c) 13. (b)

4. (d) 14. (a)

5. (b) 15. (b)

6. (d) 16. (c)

7. (b) 17. (d)

8. (a) 18. (a)

9. (b) 19. (2.7)

10. (c) 20. (b)

21. (5)

22. (c)

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 Rank Improvement Workbook 7

Solution : 23
Given Mt = –100 N-m to + 400 N-m, Sut = 500 N/mm2, Syt = 300 N/mm2, R = 90%, (fs) = 2
Step I: Endurance limit stress for shaft
Se′ = 0.5 Sut = 0.5 (500) = 250 N/mm2
Cold drawn steel and Sut = 500 N/mm2,
Ka = 0.79
Assuming 7.5 < d < 50 mm Kb = 0.85
For 90% reliability, Kc = 0.897
Se = K aK bK cSe′ = 0.79(0.85)(0.897)(250) = 150.58 N/mm2
Step II: Construction of modified Goodman diagram
Using the distortion-energy theory, Sse = 0.577 Se = 0.577 (150.58) = 86.88 N/mm2
(a) Ssy = 0.577 Syt= 0.577(300) = 173.1 N/mm2

1 1
(b) (Mt)m = [(Mt )max + (Mt )min ] = [400 − 100] = 150 N-m
2 2

1 1
(Mt)a = [(Mt )max + (Mt )min ] = [400 + 100] = 250 N-m
2 2

(Mt )a 250
tan θ = = = 1.67
(Mt )m 150

θ = 59.04°
The modified Goodman diagram for this example is shown in figure.
E
τa
θ
τa τm
X
(86.88)Sse A
B

θ = 59.04° 45° C
τm
O Ssy
(173.1)

Step III: Permissible shear stress amplitude

Refer to figure. The ordinate of point X is Sse or 86.88 N/mm2.
∴ Ssa = 86.88 N/mm2.
Step IV
IV:: Diameter of shaft
Ssa 16(Mt )a Ssa
Since τa = ; ∴ =
(fs) πd 3 (fs)
16(250 × 103 ) 86.88
3 =
πd 2
d = 30.83 mm

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 • Machine Design
8 Mechanical Engineering

Solution : 24
Given: m = 50 kg, h = 25 mm, l = 250 mm, Syt = 400 N/mm2, (fs) = 2, E = 207000 N/mm2
Step I: Impact stress (σi)
⎡ 2h ⎤
σi = σs ⎢1+ 1+ ⎥ ...(i)
⎣⎢ δs ⎦⎥
Step II: Static stress (σs)
For simply supported beam, W = m g = 50(9.81) = 490.5 N
W l 490.5(250)
Mb = = = 30656.25 N-mm
4 4
bd3 a(a)3 a4 a
I = = = mm4, y=
12 12 12 2
where a is the side of square cross-section. Therefore,
⎛a⎞
(30656.25) ⎜ ⎟
M y
σs = σb = b = ⎝ 2 ⎠ = 183973.5 N/mm3
I ⎛a ⎞4
a3
⎜⎜ ⎟⎟
⎝ 12 ⎠

Wl 3 (490.5)(250)3(12) 9256.11
Step III: Static deflection δs = = = mm
48 E I 48(207000)a4 a4
Step IV
IV:: Cross-section of beam
Equating impact stress to permissible stress,
Syt 400
σi = = = 200 N/mm2
(fs ) 2
Substituting the values of σs, σi and δs in equation (i)

183973.5 ⎡ 2(25)a 4 ⎤
200 = ⎢ 1 + 1 + ⎥
a3 ⎢⎣ 9256.11 ⎥
⎦

a3 ⎡ 2(25)a 4 ⎤
or = ⎢1 + 1 + ⎥
919.87 ⎢⎣ 9256.11 ⎥
⎦

2
⎛ a3 ⎞ a4
⎜ 919.87 − 1⎟ = 1+
⎝ ⎠ 185.12
On solving a = 67.808 (or) 70 mm
The cross-section of the beam is 70 × 70 mm

183973.5
Check for Impact Stress: σs = = 0.5373 MPa
3

9256.11
δs = = 3.855 × 10 −4 mm
a4

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 Rank Improvement Workbook 9

from equation (i): σi = 193.68 N/mm2

σi < 200 MPa
Hence, design is safe.

Solution : 25
D0
Given: Bending moment (m) = 40 N-m, Twisting moment (T ) = 50 N-m, = 2, σyt = 280 MPa, FOS = 2,
Di
kb = 1.5, kt = 1.0
Using ASME Code, permissible shear stress,
τmax = 0.30 σyt = 0.30 × 280 = 84 Mpa
Z max 84
(Zpermissible) = = = 42 MPa
FOS 2

Also, Equivalent Torque, Te = (kb m)2 + (ktT )2 = (1.5 × 40)2 + (1 × 50)2

Te = 78.102 N-m
On the basis of maximum shear stress theory,
T
τ =
ZP
ZP = Polar section modulus

π 3 ⎡ ⎛ Di ⎞ ⎤
4
π 3 ⎡
D0 × 1 − (0.5) ⎤ = 0.1839D03
4
= D0 ⎢1 − ⎜ ⎟ ⎥ =
16 ⎢ ⎝ D0 ⎠ ⎥ 16 ⎣ ⎦
⎣ ⎦
Te
∵ τ =
ZP

78.102 × 103
42 = = ZP = 1859.57 mm3
ZP
ZP = 0.1839 D03
D0 = 22 mm
D0
and Di = = 11 mm
2
Solution : 26
Stress concentration is the localized stress considerably higher than average, even in uniformly loaded
cross-section of uniform thickness due to abrupt change in the geometry or localised loading. Stress
concentration factor is not considered harmful for ductile materials in static loading because of the
phenomenon of local yielding in ductile materials when relieves the stress concentration. When the stress
in the vicinity of the discontinuity reaches the yield point there is a plastic deformation, resulting in re-
distribution of stresses. This plastic deformation prevents the harmful effects of stress concentration in
ductile materials.
While in Brittle materials, stress concentration factor is important in both static and dynamic loading. Brittle
materials fail due to fracture. So there is little deformation to relax the concentrated stresses and thus has
damaging effects.

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 3 Theory of Failure &
Spring

1. (d) 11. (c)

2. (c) 12. (a)

3. (d) 13. (b)

4. (b) 14. (d)

5. (d) 15. (b)

6. (b) 16. (c)

7. (c) 17. (2118)

8. (b) 18. (c)

9. (c) 19. (c)

10. (b) 20. (a)

21. (a)

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 Rank Improvement Workbook 11

Solution : 22
Given data: nA = nB, lA = lB, GA = GB, DA = 90 mm, DB = 60 mm, W = WA + WB = 210 N, dA = 12 mm,
dB = 7 mm
∵ Compression in both the springs are same
∴ δA = δB
⎛ 8 WD3n ⎞ ⎛ 8 WD3n ⎞
⎜ ⎟ = ⎜ ⎟
⎝ Gd 4 ⎠ A ⎝ Gd 4 ⎠ B
WA ⋅ D A3 WBDB3
∴ =
d A4 dB4
WA 4 3
d 4 D3 ⎛ 12⎞ ⎛ 60 ⎞
= A4 × B3 = ⎜ ⎟ × ⎜ ⎟ = 2.56
WB dB D A ⎝ 7⎠ ⎝ 90⎠
WA + WB = 210
(2.56 + 1)WB = 210
210
WB = = 59 N; WA = 151 N
3.56
Shear stress in spring A
8 WADA 8 × 151 × 90
τA = = = 20 N/mm2
πd A3 π × 123
Shear stress in spring B
8 WB DB 8 × 59 × 60
τB = = = 26.3 N/mm2
π dB3
π × 73

Solution : 23
(i) If axial force P is applied on the spring work done by axial force P is converted into strain energy and
stored in the spring.
strain energy U = work done by P
Mt
= (Average torque) × (angular displacement) = ×θ
2
Mt × l
But θ= (from torsion equation)
JG
⎛ PD ⎞
Where Mt = torque acting on spring wire = ⎜⎝ ⎟
2 ⎠
l = length of the spring wire = (π D n)
⎛ πd 4 ⎞
J = polar moment of inertia of the wire = ⎜ ⎟
⎝ 32 ⎠
G = Shearing modulus
Substituting these values in equation we get
4P 2D3N
Strain energy U=
Gd 4

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 • Machine Design
12 Mechanical Engineering

Now according to Castigliano’s theorem, the displacement corresponding to force P is obtained by

partially differentiating strain energy w.r.t. that force.

∂U ∂ ⎛ 4P 2D 3N ⎞ 8PD 3N
δ= = =
∂P ∂P ⎜⎝ Gd 4 ⎟⎠ Gd 4
Where δ = axial deflection of the spring (mm)
The stiffness of the spring (k) is defined as the force required to produce unit deflection. Therefore,

P Gd4 Gd4
K= = =
δ 8 D3 n 8D3 n
D
(ii) =6 (Given)
d
Also deflection δ = 3 cm
Axial load P = 500 N
Shearing modulus G = 80 GPa = 80 × 109 N/m2

8PD 8P ⎛ D ⎞
Now, τ= = ⎜ ⎟
πd 3 πd 2 ⎝ d ⎠

8 × 500
⇒ 300 × 106 = ×6
πd2

8 × 500 × 6
d2 =
π × 300 × 106
d = 5.05 mm

8PD 3
Also, δ= n
Gd 4
3
⎛D⎞
8 × 500 × ⎜ ⎟ × n
⎝d⎠ D
3 × 10–2 = 9
, where = 6, spring index
80 × 10 × d d

3 × 10 −2 × 80 × 109 × d 240 × 107 × 5.05 × 10−3

n= =  14
⎛D⎞
3
8 × 500 × (6)3
8 × 500 × ⎜ ⎟
⎝d⎠

Hence number of active coils = 14

D
As =6
d
D = 6 × d = 30.3 mm
∴ Length of spring wire = π n D = π × 14 × 30.3
= 1.33 m

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 Rank Improvement Workbook 13

Solution : 24
Given data: NA = 9; NB = 8; δA = 8 mm; δB = 3 mm; DA = 80 mm; DB = ?
8PD A3 N A 8PDB3 NB
δA = and δB =
Gd 4 Gd 4
3
δB ⎛ DB ⎞ NB
= ⎜
δA ⎝ D A ⎟⎠ N A
3
3 9 ⎛ DB ⎞
or × = ⎜
8 8 ⎝ D A ⎟⎠
3
⎛ DB ⎞ 33
or ⎜⎝ D ⎟⎠ =
A 43
DB 3
or =
DA 4
∴ DB = 0.75 × 80 = 60 mm

Solution : 25
Given: P = 2000 N, δ = 5 mm, C = 5, A = 1753, m = 0.182, G = 81370 N/mm2, τ = 0.5 Sut
Permissible shear stress
A 1753
Sut = m
= 0.182
d d
0.5(1753) 876.5
τ = 0.5 × Sut = = 0.182 N/mm2
d 0.182 d
Wire diameter
4C − 1 0.615 4(5) − 1 0.615
K = + = + = 1.3105
4C − 4 C 4(5) − 4 5

τ = K ⎛⎜
8PC ⎞ 876.5 ⎧ 8(2000)(5) ⎫
2⎟
or 0.182 = (1.3105) ⎨ 2 ⎬
⎝ πd ⎠ d ⎩ πd ⎭
d2 1.3105(8)(2000)(5)
= 38.07
=
d 0.182 π(876.5)
d1.818 = 38.07 or d = (38.07)(1/1.818)
∴ d = 7.40 or 8 mm (i)
Mean coil diameter
D = C d = 5(8) = 40 mm (ii)
Number of active coils

8PD3N 8(2000 − 1000)(40)3N

From equation δ = 4
or 5 =
Gd (81370)(8)4
∴ N = 3.25 or 4 coils (iii)
Total number of coils
For square and ground ends, the number of inactive coils is 2. Therefore,
Nt = N + 2 = 4 + 2 = 6 (iv)

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 • Machine Design
14 Mechanical Engineering

Solid length of spring

solid length of spring = Ntd = 6(8) = 8 mm (v)
Free length of spring
The actual deflection of the spring under the maximum force of 2000 N is given by,
8PD3N 8(2000)(40)3(4)
δ = = = 12.29 mm
Gd 4 (81370)(8)4
It is assumed that there will be a gap of 0.5 mm between the consecutive coils when the spring is
subjected to the maximum force of 2000 N. The total number of coils is 6. Therefore, total axial gap will
be (6 – 1) × 0.5 = 2.5 mm
Free length = solid length + total axial gap + δ
= 48 + 2.5 + 12.29 = 62.79 or 63 mm ...(vi)
Required spring rate
P1 − P2 2000 − 1000
k = = = 200 N/mm ...(vii)
δ 5
Actual spring rate
Gd4 (81370)(8)4
k = = = 162.74 N/mm ...(viii)
8D3N 8(40)3(4)

Solution : 26
Initial compression of spring, δ1 = 30 mm
Further compression of spring, δ = 50 mm
Total compression of spring, δ2 = 30 + 50 = 80 mm
Energy absorbed by the spring, E = 250 J = 250 N-m = 250 × 103 N-mm
Spring index, C = 6
Sut = 1500 N/mm2
G = 81370 N/mm2
Permissible shear stress, τper = 0.3 Sut
Sut = 0.3 × 1500 = 450 N/mm2
To find:
(i) Wire diameter (d )
(ii) Number of active turns (n)
(iii) Free length (Lf)
(iv) Pitch of the turns (p)
Step 1: Calculate the wire diameter of spring
Let, W1 be the load required for initial compression of spring δ1 and W2 be the total load required for total
compression of spring δ2 we know that,
W1
K = ∴ W1 = Kδ1 = 30 K,N
δ1
W2
Similarly, K = ∴ W2 = Kδ 2 = 80K,N ...(ii)
δ2
30K + 80K
Now, average load during compression = = 55 K , N
2

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 Rank Improvement Workbook 15

Energy absorbed during shock is, E = Average force × Further compression of spring
∴ 250 × 103 = 55 K × 50
∴ K = 90.909 N/mm
∴ W2 = 80 K = 80 × 90.909 = 7272.72 N
4C − 1 0.615 4 × 6 − 1 0.615
Wahl’s factor is, KW = + = + = 1.2525
4C − 4 C 4×6−4 6
8W2C
Maximum shear stress is, τper = × KW
πd 2
8 × 7272.72 × 6
∴ 450 = × 1.2525
πd 2
∴ d = 17.5863 mm  18 mm
∴ D = Cd = 6 × 18 = 108 mm
Step 2: Calculate the number of active turns
Gd
Spring rate is, K =
8C 3n
81370 × 18
∴ 90.909 =
8 × 63 × n
∴ n = 9.3236  10 turns
Step 3: Calculate the free length of the spring

8W2C 3n 8 × 7272.72 × 63 × 10
The maximum deflection is, δmax = =
Gd 81370 × 18
∴ δmax = 85.8032 mm
Assuming squared and ground ends,
∴ n ′ = n + 2 = 10 + 2 = 12
Free length is, LF = n ′d + δ max + 0.15 δ max
∴ LF = 12 × 18 + 85.8032 + 0.15 × 85.8032
∴ LF = 314.6737 mm  315 mm
Step 4: Calculate the pitch of the turns

Free length 314.6737

Pitch of the turns is, p = =
n′ − 1 12 − 1
∴ p = 28.6067 mm

Solution: 27
Let M = Bending moment and T = Twisting moment
(i) Equivalent bending moment

Me =
1
2 (
M + M2 + T 2 =
1
2) (
3T + 9T 2 + T 2 )
=
T
2
( )
3 + 10 = 3.08114 T

370
Safe stress in bending, σ = = 92.5N/mm 2
4

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 • Machine Design
16 Mechanical Engineering

πd 3
Me = σ
32
100 3 1
∴ 3.08114 T = 92.5π × × 6 kNm
32 10
T = 2.947 kNm
(ii) Equivalent torque, Te = M 2 + T 2 = 9T 2 + T 2 = T 10
σ 92.5
Safe stress, τs = = = 46.25N/mm 2
2 2

πd 3
Te = τ s ·
16

100 3 1
T 10 = 46.25π × × 6 kNm
16 10
T = 2.872 kNm

Solution : 28
Given data: d = 50 mm; M = 1.5 kNm; σy = 210 MPa
(i) According to maximum principal stress theory
σ1 < σper
In this case combine bending and twisting moment
1⎡ 1
⎣M + M + T ⎤⎦ = ⎡⎣1.5 + (1.5) + T ⎤⎦
2 2 2 2
Me =
2 2
32Me M
Bending stress, σb =
πd 3

π 1⎡ φ = 50 mm
∴ 210 × (50)3 = 1.5 + (1.5)2 + T 2 ⎤⎦ × 106
32 2⎣
T = 3.3321 kNm T
(ii) According to maximum shear stress theory
σy 210
τmax = = = 105 MPa
2 2
In this case combine twisting and bending moment is

Te = T 2 + M2 = T 2 + (1.5)2 × 106

16Te
Shear stress, τ =
πd 3

π
105 × (50)3 = T 2 + (1.5)2 × 106
16
T = 2.0955 kN.m

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 Rank Improvement Workbook 17

Solution : 29
Given: σ1 = 60 N/mm2 and σ2 = –36 N/mm2
σyt = 100 N/mm2
(i) Factor of safety according to maximum principal stress criteria
σyt
σ1 ≤
fos
100
60 ≤
fos
fos = 1.67
(ii) Factor of safety according to maximum shear stress criteria
σyt
τmax ≤
2fos
σ1 − σ2 60 + 36
τmax = = = 48 N/ mm2
2 2
100
48 ≤
2fos
fos = 1.04
(iii) Factor of safety according to maximum strain energy criteria
2
⎛ σ yt ⎞
σ12 + σ22 − 2μσ1σ2 ≤ ⎜ fos ⎟
⎝ ⎠
2
⎛ 100⎞
(60)2 (–36)2 + 2 × 0.3 × 60 (36) ≤ ⎜
⎝ fos ⎟⎠
+
2
⎛ 100⎞
3600 + 1296 + 1296 ≤ ⎜
⎝ fos ⎟⎠
100
fos =
= 1.27
79.69
(iv) Factor of safety according to maximum distortion energy criteria or maximum shear strain energy criteria
2
⎛ σ yt ⎞
σ12 + σ22 − σ1σ2 ≤ ⎜ fos ⎟
⎝ ⎠
2
⎛ 100⎞
(60)2 + (–36)2 + 60 × 36 ≤ ⎜
⎝ fos ⎟⎠
2
⎛ 100⎞
3600 + 1296 + 2160 ≤ ⎜
⎝ fos ⎟⎠
100
84 ≤
fos
100
fos = = 1.19
84

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 4 Welded joint, Riveted joint
and Bolted Joints

1. (c) 17. (d)

2. (b) 18. (b)

3. (c) 19. (b)

4. (d) 20. (d)

5. (a) 21. (d)

6. (d) 22. (a)

7. (b) 23. (a)

8. (b) 24. (b)

9. (a) 25. (42.43)

10. (a) 26. (b)

11. (a) 27 (c)

12. (c) 28. (c)

13. (d) 29. (3.22)

14. (c) 30. (0.75)

15. (b)
„„„„

16. (d)

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 Rank Improvement Workbook 19

Solution : 31
Diameter of rivet hole, d = 6 t = 6 12.5 = 21.2 mm
As per table, for the rivet hole of 21.5 mm size, diameter of rivet is 20 mm. This size is standard size.
∴ Diameter of rivet, d = 20 mm
Let, n = number of rivets
Pt = Maximum pull on the joint i.e. tearing resistance of plate at the outer row which has only one rivet.
Pt = (b – d ) t × σt = (200 – 21.5) × 12.5 × 80 = 178,500 N
π 3.14
Shearing resistance of one rivet, Ps = 1.75 × × d 2 × τ = 1.75 × × (21.5)2 × 65
4 4
∴ Ps = 41,300 N
Crushing resistance of one rivet, Pc = 21.5 × 12.5 × 160 = 43000 N
Pt 178,500
Number of rivets, n = = = 4.32
Least of Ps or Pc 41,300
∴ n = 5

Solution : 32
Given diameter, d = 5 cm = 50 mm
size of the fillet, s = 1 cm = 10 mm
8000
permissible shear stress,τs = 8 kN/cm2 = N / mm2 = 80 N/mm2
100
we know that maximum shear stress, (τmax)
2.83T 2.83T
τmax = ⇒ = 80 N/mm2
πsd 2
π × 10 × 502
80 × π × 10 × 502
⇒ T = = 2.22 × 106 N-mm = 2.22 kN-m
2.83
T = torque applied on the shaft t
d = diameter of the shaft
Weld
S = leg or (side) of the weld
t = throat thickness
J = polar moment of inertia d
T
3 45°
πtd s
=
4
T τ
We know that, =
J r
T T d 2T
τ = ×r = × =
J πtd 3 2 πtd 2
4
But maximum shear stress occurs at the throat of the weld which is inclined at 45° to the horizontal plane
2T 2.83T
∴ τmax = = (∵ t = s sin 45°)
π s(sin45°)d 2
πsd 2

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 • Machine Design
20 Mechanical Engineering

Solution : 33
Given: Eccentric load = 12.5 kN, Zmax = 40 MPa = 40 N/mm2
3
Primary shear force on each rivet
p 12.5
P′ = = = 2500 N r 100
5 5
r= 1002 + 1002 ⇒ 141.42 mm 1

e = 100 + 50 + 400 = 550 mm 100

Secondary shear force on rivet (3)

Per1
P ′′ = [∵ rs = 0]
r12 + r22 + r32 + r42 + r52

(12.5 × 103) × 550 × 141.42

P ′′ =
4 × (141.42)2 P ′′
P ′′ = 12153.28 N θ 3

100
tan θ = =1 P′
100
θ = (45°)
θ
So, resultant force on rivet (3), 1

Presultant = (P′ + P′′ sinθ )2 + (P′′ cos θ)2

= (2500 + 12153.28sin45°)2 + (12153.28cos45°)2

= (123069440.9) + (73851122.57)
Presultant = 14032.83 N
Let, A = Cross sectional area of rivet
Presultant
τmax =
A
14032.83
A= mm2 = 350.82 mm2
40
π 2
As, A=d = 350.82
4
d = 21.140 mm
or from preferred series (given) d = diameter of rivet = 22 mm
Solution : 34
Given, t = 20 mm, d = 25 mm, p = 100 mm, σt = 120 MPa, σc = 150 MPa, τ = 100 MPa
Tearing resistance of the plate
Ft = (p – d) t σ t = (100 – 25) × 20 × 120 = 180 kN
Shearing resistance of the rivets
π 2 π
Fs = n × 2 × d × t = 2 × 2 × (25)2 × 100 = 196.375 kN
4 4
Crushing resistance of the rivets
Fc = n × d × t × σt = 2 × 25 × 20 × 150 = 150 kN

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 Rank Improvement Workbook 21

∴ Strength of the joint = min{ft , fs, fc} = 150 kN

Strength of the unriveted or solid plate, F = p × t × σt = 100 × 20 × 120 = 240 kN
least of Ft , Fs and Fc 150000
∴ Efficiency of the joint = = = 0.625 or 62.5 %
F 240000
Solution : 35

5.66M
(i) σb(max) =
πsd 2
M = PL = 5 × 103 × 200 = 1 × 106 Nmm
d = 50 mm
σb(max) = 100 N/mm2
5.66 × 1× 106
s = = 7.21 mm or 8 mm
3.14 × 100 × 50 × 50

(ii)
2.83T
τmax =
πsd 2
Given, T = 3 kNm = 3 × 106 Nmm
d = 65 mm
τmax = 70 MPa = 70 N/mm2
s = size of weld
2.83T
s =
π τmaxd 2

2.83 × 3 × 106
s = = 9.14 mm or 10 mm
3.14 × 70 × 65 × 65

Solution : 36
Given: t = 15 mm
d = 25 mm;
p = 75 mm
σtu = 400 MPa = 400 N/mm2 ; τu = 320 MPa
= 320 N/mm2
σcu = 640 MPa = 640 N/mm2
Minimum force per pitch which will rupture the joint
Since the ultimate stresses are given, therefore we shall find the ultimate values of the resistances of the
joint. We know that ultimate tearing resistance of the plate per pitch,
Ptu = (p – d ) t × σtu = (75 – 25)15 × 400 = 300000 N
Ultimate shearing resistance of the rivets per pitch,
π
Psu = n × × d 2 × τu
4
π
= 2× (25)2 320 = 314200 N (∵ n = 2)
4
and ultimate crushing resistance of the rivets per pitch,
Pcu = n × d × t × σcu = 2 × 25 × 15 × 640 = 480000 N

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 • Machine Design
22 Mechanical Engineering

From above we see that the minimum force per pitch which will rupture the joint is 300000 N or 300 kN
Actual stresses produced in the plates and rivets
Since the factor of safety is 4, therefore safe load per pitch length of the joint
= 300000/4 = 75000 N
Let σta, τa and σca be the actual tearing, shearing and crushing stresses produced with a safe load of 75000
N in tearing, shearing and crushing.
We know that actual tearing resistance of the plates (Pta ),
75000 = ( p – d )t × σta = (75 – 25)15 × σta = 750 σta
75000
∴ σta = = 100 N/mm2 = 100 MPa
750
Actual shearing resistance of the rivets (Psa),
π π
× d 2 × τa = 2 × (25) τa = 982 τa
2
7500 = n ×
4 4
75000
∴ τa = = 76.4 N/mm2 = 76.4 MPa
982
and actual crushing resistance of the rivets (Pca),
75000 = n × d × t × σca = 2 × 25 × 15 × σca = 750 σca
75000
∴ σca = = 100 N/mm2 = 100 MPa
750

Solution : 37
Width = 100 mm
Thickness = 12.5 mm
Load, P = 60 kN = 60 × 103 N
τmax = 56 MPa = 56 N/mm2
Length of weld for static loading
Let l = length of weld
s = weld size = plate thickness = 12.5 mm
Maximum load carried by plate is dependent upon type of parallel fillet weld whether it is single or double,
so the maximum load will be carried by double parallel fillet welds.
60 × 103 = 1.4145 × l × τ
60 × 103 = 1.414 × 12.5 × l × 56
or l = 60.62 mm
Adding 12.5 mm for starting and stopping of weld run,
Design length of weld = 60.62 + 12.5 = 73.12 mm
Length of weld for fatigue loading
τstatic 56
Permissible stress, τ = = = 20.74 N/mm2
Stress concentration factor 2.7
Maximum load = 2 × 0.7075 × l × τ
60 × 103
l = = 163.675 mm
1.414 × 12.5 × 20.74
Adding 12.5 mm for starting and stopping of weld run,
Design length of weld = 163.675 + 12.5 = 176.175 mm
(Selecting the higher length for the design purpose)

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 Rank Improvement Workbook 23

Solution : 38
Steam pressure on cylinder head,
P = 0.7 N/mm2
Number of bolts, n = 12
Effective cylinder diameter, D = 300 mm
Tensile stress, σt = 100 MPa = 100 N/mm2

π 2 3.14
× (300 ) × 0.7 = 49490 N
2
Total external load = D ×P =
4 4
External load on the cylinder head for one bolt,

49490
P2 = = 4124 N
12
Let d = nominal diameter of the bolt, and
dc = core diameter of the bolt (dc = 0.84 d)
Initial tension due to tightening of bolt,
P1 = 2840 d N
Resultant axial load, P = P1 + kP2
a
= P1 + P
1+ a 2
1
a = 1, k = = 0.5
2
π 2
P = d
4 c
π
× ( 0.84 d ) × 100 = 55.4 d 2
2
σt =
4
Now, P = 2840 d – 2062 = 55.4 d 2
or 55.4 d 2 – 2840 d – 2062 = 0
d 2 – 51.3 d – 37.2 = 0

51.3 ± (51.3 ) + 4 × 37.2 51.3 ± 52.7

2
∴ d = = = 52 mm
2 2
Size of bolt = M52

„„„„

© Copyright www.madeeasypublications.org
 5 Clutches and Brakes

1. (b) 13. (d)

2 (a) 14. (d)

3. (c) 15. (1738.13)

4. (b) 16. (c)

5. (d) 17. (a)

6. (a) 18. (39.5)

7. (a) 19. (1173.54)

8. (c) 20. (a)

9. (d) 21. (d)

10. (a) 22. (d)

11. (0.127) 23. (b)

„„„„
12. (c)

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 Rank Improvement Workbook 25

Solution : 24
Given data:
Mass of vehicle, m = 110 kg
Moment of inertia of each wheel,
Iw = 0.22 kg-m2
Radius of each wheel, R = 0.35 m
Moment of inertia of engine,
ΙE = 0.7 kg-m2
Engine speed, ωE = 3 × speed of wheel = 3 × ω1
Initial velocity of vehicle, V1 = 60 km/hr = 16.667 m/sec
Distance travelled by vehicle after braking,
S = 12 m
To find Energy absorbed
Calculate the energy absorbed by each brake, (E)
(i) Kinetic energy of vehicle is

Ev =
2
1
( )1
m V12 − V 22 = × 110 × ⎡(16.667) − 0⎤
2 ⎣
2
⎦
... ( ∵ V2 = 0)

∴ Ev = 15.2783 × 10 J 3

Initial angular velocity of wheel is,

V1 = R.ω1 ⇒ ∴ 16.667 = 0.35 × ω1
∴ ω1 = 47.62 rad/sec
(ii) Kinetic energy of two wheels is,

Ew = 2 ×
2
1
( ) 1
Ι w ω 12 − ω 22 = 2 × × 0.22 × ⎡( 47.62 ) − 0 ⎤
2 ⎣
2
⎦
...(∵ ω2 = 0)
∴ Ew = 498.8861 J
Initial angular velocity of engine is,
ωE1 = 3 × ω1 = 3 × 47.62 = 142.86 rad/sec
(iii) Kinetic energy of engine is,

EE =
1
2
( ) 1
I E ω E2 1 − ω E2 2 = × 0.7 ⎡(142.86) − 0 ⎤ ...(∵ ωE2 = 0)
2 ⎣
2
⎦
∴ EE = 7.1431 × 103 J
(iv) Now, total energy absorbed by brakes is,
ET = Ev + Ew + EE = 15.2783 × 103 + 498.8861 + 7.1431 × 103
∴ ET = 22.9202 × 103 J
Energy absorbed by each brake is,

Total energy E 22.9202 × 103

E = = T =
Number of brakes 2 2
∴ E = 11.4601 × 103 J

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 • Machine Design
26 Mechanical Engineering

Solution : 25
Maximum torque produced by the engine,
Tmax = 200 N-m
Rotational speed, N = 2000 r.p.m.
Clutch outer diameter, d1 = 230 mm
= r1 = 115 mm
Coefficient of friction, μ = 0.3
Permissible pressure, pmax = 0.25 N/mm2
Using uniform wear theory:
We know that w = 2πC(r1 – r2), where pmax × r2 = C
and T = n μ ω R,
r1 + r2
where, R =
2
Taking maximum torque, i.e.
Tmax = 200 N-m
(115 + r2 )
200 × 103 N-m = 2 × 0.3 × 2π × 0.25 × r2 (115 − r2 ) ×
2
(∵ For a single disc or plate clutch, both sides of the discs are effective, i.e., n = 2 and r2 → inner radius)
424413.18 = (1152 – r22)r2
By hit and trial method, we get
r2  93 mm
Hence clutch inner radius = 93 mm = r2
Outer radius = 115 mm (given) = r1
Hence width of the clutch plate,
w = r1 – r2 = 22 mm
60 × 1000
Speed of the car = 60 km/hr = V = m/s
3600
V 710
∴ Final angular speed ωf = × GR (r → radius of the wheel, = mm , = 0.355 m)
r 2
(GR → Gear reduction = 4.12)
60 × 1000
ωf = 3600 × 4.12 = 193.42 rad/s
⎛ 710 ⎞
⎜⎝ 0. ⎟
2 ⎠
Initial angular velocity (at the time of engagement),
2 × π × 2000
ωi = = 209.43 rad/s
60
Initial angular acceleration at the time of engagement,
T1 − T2 100 − 200
αi = = = – 66.67 rad/s2
I 1.5
where, I - mass moment of inertia of engine side = 1.5 kg-m2
T1 - torque at the time of engagement
Torque available at the rear wheels, T = 105 N-m = 105 × 103 N-mm (Given)

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 Rank Improvement Workbook 27

T
Accelerating force on automobile F =
Radius of the wheel
105 × 103 N-mm
= 295.77 N
355
F 295.77N
Acceleration, at = = = 0.1971 m/s2
mass of car 1500kg
Final angular acceleration,
0.1971
αf = × GR = 2.288 rad/s2
0.355
GR → Gear reduction = 4.12 (Given)
ω i − ωf 209.43 − 193.42
ΔT = = = 0.2321 sec.
αf − α i 2.288 − (−66.67)
Solution : 26
Given, Power, P = 15 kW
2 πN 2π × 720
N = 720 r.p.m. = ω = = = 75.39 rad/s
60 60
Number of shoes, n = 4
325
Inside radius of the drum, R = = 162.5 mm = 0.1625 m
2
Radial distance of C.G. of each shoe from the axis shaft r = 120 mm
Coefficient of friction, µ = 0.25
Since the speed at which engagement begins (ω1) is 80% of full speed (ω) therefore
ω1 = 0.8 × ω = 0.8 × 75.39 = 60.312 rad/s
Power transmitted P = Tω
15 × 103 = T × 75.39
T = 198.96 N-m
(i) Mass of each shoe:
Let the mass of each shoe be m kg
Centrifugal force acting on each shoe, Pc = mω2r
= m x (75.39)2 × 0.12 = (682.03 m)N
The inward force on each shoe exerted by the spring i.e., centrifugal force at the engagement speed ω1,

Ps = mω12r = m × (60.312)2 × 0.12

= (436.5 m)N
Frictional force acting tangentially on each shoe,
F = µ(Pc – Ps) = 0.25 (682.03 m – 436.5 m)
= (61.38 m)N
Torque transmitted, T = nFR
198.96 = 4 × 61.38 m × 0.1625 = m = 4.986 kg
(ii) Size of the shoe:
Let, l = Contact length of shoe in mm,
b = Width of the shoe in mm,
θ = Angle subtended by the shoes at the centre of the

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 • Machine Design
28 Mechanical Engineering

spider in radians,
π
= 60° = radian
3
P = Pressure exerted on the shoe in N/mm2
= 0.1 MPa = 0.1 N/mm2
π
We know that l = Rθ = 162.5 × = 170.16 mm
3
and lbp = Pc – Ps = 682.03 m – 436.5 m = 170.16 × b × 0.1
= 245.53 m
= 245.53 × 4.986
⇒ b = 71.94 mm  72 mm
∴ Contact length of the shoe, l = 170.16 mm
and width of the shoe, b = 72 mm
Spring design:
436.5 × 4.986
Centrifugal force on each spring, Ps = = 544.69 N
4
Given, C = 6,
τ(shear stress) = 600 MPa = 600 × 106 N/m2
8PsC ⎧ 4C − 1 0.615 ⎫
We know that τ = ⎨ + ⎬
πd 2 ⎩ 4C − 4 C ⎭
8 × 544.09 ⎧ 4 × 6 − 1 0.615 ⎫
600 × 106 = × 6⎨ + ⎬
πd 2
⎩4 × 6 − 4 4 ⎭
d = 4.25 × 10–3 m = 4.25 mm
and D = md = 6 × 4.25 = 25.5 mm
8Ps D 3n
And δ = , δ → radial clearance = 0.01 m = 10 mm
Gd 4
δGd 4 0.01× (80 × 103 × 106 ) × (0.00425)4
n = =
8Ps D 3 8 × 544.09 × (0.0255)3
n = 3.616  4 (take)
∴ Number of active turns of the coil, n = 4.

Solution : 27
Given: m = 2500 kg, v1 = 1.5 m/s, v2 = 0,
For drum, m = 50 kg, k = 0.7 m, h = 0.5 m, R = 0.75
KE of the mass:
1 1
KE = m (v12 − v22 ) = (2500)[(1.5)2 − 0]
2 2
= 2812.5 J (a)
v1 1.5
KE of the drum: ω1 = = = 2 rad/s and ω 2 = 0
R 0.75
1 1
KE = mk 2 (ω12 − ω22 ) = (50)(0.7)2 [(2)2 − 0] = 49 J (b)
2 2

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 Rank Improvement Workbook 29

PE of the mass PE = m g h = (2500) (9.81) (0.5) = 12262.5 J (c)

The total energy absorbed by the brake is given by,
E = 2812.5 + 49 + 12262.5 = 15124 J (i)
Step II: Torque capacity of brake
During the braking action, the mass moves through a distance of 0.5 m. If θ is the angle through which the
drum rotates during the braking period.
θ × (drum radius) = 0.5; θ × (0.75) = 0.5
0.5
or θ = = 0.667 rad ;
0.75
E 15124
∴ Mt = = = 22686 N-m (ii)
θ 0.667

Solution : 28
Given: D = 1 m, t = 0.2 m, n1 = 350 rpm, t = 1.5 s
Step I: Energy absorbed by brake
The brake absorbs the kinetic energy of the rotating flywheel. The mass density of cast iron is taken as
7200 kg/m3. The mass of flywheel is given by,
π 2 π
m = D t ρ = (1)2 (0.2)(7200) = 1130.97 kg
4 4
The radius of gyration (k) of solid disk about its axis of rotation is (d / 8) .

D2 1 2
k2 = = m
8 8
2πn1 2π(350)
ω1 = = = 36.65 rad/s
60 60
and ω2 = 0
1 2 2 1 ⎛ 1⎞
E = mk (ω1 − ω 22) = (1130.97) ⎜⎝ ⎟⎠ (36.65)2
2 2 8
= 94946.52 J ...(i)
Step II: Torque capacity of brake
The average velocity during the braking period is (ω1 + ω2)/2 or (ω1/2). Therefore
⎛ ω1⎞ ⎛ 36.65⎞
θ = ⎜⎝ ⎟⎠ t = ⎜⎝ ⎟ (1.5) = 27.49 rad
2 2 ⎠
E 94946.52
Mt = = = 3453.86 N-m ...(ii)
θ 27.49

Solution : 29
Given: Mt = 1500 N-m, Ro = 150 mm, Ri = 100 mm, pa = 2 MPa, μ = 0.35, number of pads = 2
Step I: Actuating force
Since, there are two pads, the torque capacity of one pad is (1500/2) or 750 N-m
2 (Ro3 − R3i ) 2 (1503 − 1003 )
Rf = = = 126.67 mm
3 (Ro2 − R2i ) 3 3(1502 − 1002 )
Mt = μ PR f
750(103) = 0.35 P(126.67) or P = 16916.85 N

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 • Machine Design
30 Mechanical Engineering

Step II: Angular dimension of pad

P = average pressure × area of pad
16916.85 = 2 A or A = 8458.42 mm2
1
A = θ(Ro2 − Ri2 )
2
1
or 8458.42 = θ(1502 − 1002 )
2
⎛ 180⎞
θ = 1.3533 radians or θ = 1.3533 ⎜ = 77.54°
⎝ π ⎟⎠
The angular dimension of of pad can be taken as 80°.

Solution : 30
Power, P = 15 kW
2πN 2π × 720
ω = = = 75.39 rad/s
60 60
Number at shoes, n = 4
325
Inside radius of the drum, R = = 162.5 mm = 0.1625 m
2
μ = 0.2
Engagement speed, ω1 = 80% of full speed
ω1 = 0.8 × 75.39 = 60.312 rad/s
P 15 × 103
Torque, T = = = 198.96 Nm
ω 75.39
(i) Mass of each shoe
Let mass of each shoe be m kg.
Centrifugal force acting on each shoe, Pc = mω2 r
Pc = m(75.39)2 × 0.12
Pc = (682 m)N
Tangential frictional force, F = μ(Pc – Ps)
Torque, T = nFR
T = n μ(Pc –Ps)R
or 198.96 = 4 × 0.2 (682 – 436.5)m × 0.1625
or m = 6.234 kg
(ii) Size of the shoe
θ = angle subtended by the shoe at the centre
π
θ = 60° or radian
3
Contact length of shoe, l = R θ
π
l = 162.5 × = 170.16 mm
3
Pressure exerted on the shoe, P = 0.15 MPa = 0.15 N/mm2
l bp = Pc – Ps
l bp = (682 – 436.5) × 6.234
or (170.16) b × 0.15 = 245.5 × 6.234

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 Rank Improvement Workbook 31

or b = 59.96 mm or 60 mm
Contact length of the shoe, l = 170.16 mm
Contact width of the shoe, b = 60 mm

Solution : 31
Given: P = 45 kW = 45 × 103 W, N = 1000 rpm, α = 12.5°, D = 500 mm, or R = 250 mm, μ = 0.2,
pn = 0.4 N/mm2
(i) Face width
Let b = Face width of the clutch in mm
We know that torque developed by the clutch,
P × 60 45 × 103 × 60
T = = = 430 Nm = 430 × 103 Nmm
2 πN 2π × 1000
We also know that torque developed by the clutch (T ),
430 × 103 = 2π × μ × pn × R 2 × b = 2π × 0.2 × 0.1(250)2 b = 7855 b
∴ b = 430 × 103/7855 = 54.7 say 55 mm
(ii) Axial spring force necessary to engage the clutch
We know that the normal force acting on the contact surfaces,
Wn = pn × 2πR b = 0.1 × 2π × 250 × 55 = 8640 N
∴ Axial spring force necessary to engage the clutch,
We = Wn (sinα + 0.25μ cosα) [Experimentally found]
= 8640(sin 12.5° + 0.25 × 0.2 cos 12.5°) = 2292 N

Solution : 32
Given: n = 1440 rpm; μ = 0.2; rm = 2 b
pa = 0.1 N/mm2 ; α = 12.5°
For machine, m = 150 kg; k = 250 mm; t = 40s
Step I : Inner and outer diameters
ω1 = 0
2πn 2π (1440 )
ω2 = = = 150.80 rad/s
60 60
ω2 − ω1 150.80 − 0
α = = = 3.77 rad.s2
t 40
Mt = Iα = mk 2; α = 150(0.25)2 (3.77)
= 35.34292 Nm = 35342.92 Nmm

b D–d
2
α

D/2

d/2

fig. (a)

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 • Machine Design
32 Mechanical Engineering

πμpad 2
For cone clutch Mt =
8sin α
(
D − d2 )
π (0.2 )(0.1)d
∴ 35342.92 =
8 sin (12.5° )
(D 2
− d2 )
Rearranging the terms, we have
d (D2 – d 2) = 973978.34 ...(a)
From figure (a) D – d = 2 b sinα ...(b)
Since the mean radius of the clutch is twice the face width,
D +d
= 2b or D + d = 8 b ...(c)
4
D +d 8b 4
Dividing eq. (c) by (b), = =
D −d 2b sin α sin α

D 4 + sin α 4 + sin (12.5° )

= 4 − sin α = 4 − sin 12.5° = 1.1144
Therefore,
d ( )
D2
= 1.2419 or D 2 = 1.2419 d 2
d2
Substituting this value in eq. (a) we get
d (1.2419 d 2 – d 2) = 973978.34
0.2419d 3 = 973978.34
973978.34
d3 =
0.2419
∴ d = 159.09 mm
D = 1.1144 d = 1.1144(159.09) = 177.29 mm ...(i)
Step II: Face width of friction lining
D + d 177.29 + 159.09
From eq. (c) b = = = 42.05 mm ...(ii)
8 8
Step III: Force required to engage clutch
4Mt sin α 4 (35342.92 ) sin (12.5° )
From eq. P = = = 454.82 N ...(iii)
μ (D + d ) 0.2 (177.29 + 159.09 )
Step IV: Heat generated during each engagement
ω1 + ω2 0 + 150.8
ωave = = = 75.4 rad/s
2 2
θ = ωave (time) = 75.4 (40) = 3016 radians
Heat generated during engagement = work done by frictional torque
Hg = Mt θ = 35.34 (3016)
= 106585.44 Nm or J = 106.59 kJ ...(iv)

„„„„

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 6 Gears

1. (b)

2. (c)

3. (c)

4. (c)

5. (c)

6. (a)

7. (a)

8. (b)

9. (a)

10. (c)

11. (b)

12. (4)

13. (a)

14. (b)

15. (144.22)

16. (c)

„„„„

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 • Machine Design
34 Mechanical Engineering

Solution : 17
zp = 25, zg = 60
Power at pinion = 25 kW at 1440 rpm
CS-service factor = 1.5
σp = 140 N/mm2
σg = 70 N/mm2
Factor of safety = 1.5
Form factor for 25 teeth, Y = 0.34
Form factor for 60 teeth, Y = 0.421
∴ (σY)p = 140 × 0.34 = 47.6 N/mm2
(σY)g = 70 × 0.421 = 29.47 N/mm2
Hence gear is weak so it will be designed
b = 10 module
Beam strength of gear -Lewis equation
S = bmY σ
Pt .Cs
FoS × = (10 m) m (29.47)
Cv
1.5 × Pt × 1.5
= 294.7 m2 ... (i)
Cv
The torque to be transmitted
Power 25000
Mt = =
ω 2π × 1440
60
Mt = 165.786 × 103 N-mm
2 Mt 2 Mt
Pt = =
dp m.zp

2 × 165.786 × 103
Pt =
25 m
13262.88
Pt =
m
Assuming velocity < 10 m/sec
⎛ 3 ⎞
Cv = ⎜
⎝ 3 + v ⎟⎠

3 3 3
Cv = = =
π d p NP π × m × z pN p π × 25 × 1440 m
3+ 3+ 3+
60 60 60 × 1000
⎛ 3 ⎞
Cv = ⎜ ⎟
⎝ 3 + 1.885 m ⎠
Put Pt and Cv in equation (i)

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 Rank Improvement Workbook 35

1.5 × 1.5 13262.88

× = 294.7 m2
3 m
(3 + 1.885 m)
2.25 (3 + 1.885 m) × 13262.88
= 294.7 m2
3m
33.75 (3 + 1.885 m) = m3
m3 – 63.62 m – 101.26 = 0
which gives m = 8.68 mm
∴ The module is 10 mm
face width b = 100 mm
dia. of pinion, dp = 25 × 10 = 250 mm
which gives the velocity
πdpNP π × 0.25 × 1440
v = = = 18.85 m/sec
60 60
Hence the assumption was wrong in velocity.
∴ use the velocity factor
6
Cv = for 10 < V < 20 m/sec
6+v
⎛ 6 ⎞
∴ Cv = ⎜ ⎟
⎝ 6 + 1.885 m ⎠
Now put it in equation (i)
1.52 × 13262.88
= 294.7 m2
⎛ 6 ⎞
⎜⎝ 6 + 1.885 m⎟⎠ m

16.876 (6 + 1.885 m) = m3
m3 – 31.8 m – 101.26 = 0
This equation gives m = 6.83 mm
∴ Now available module = 8 mm
∴ dia. of pinion = 8 × 25 = 200 mm
dia. of gear = 8 × 60 = 480 mm
Face width, b = 10 m = 80 mm

Solution : 18
Given, φ = 20°
Power = 20 kW = 20 × 103 W
NP = 300 rpm
TG
Velocity ratio = =3,
TP
σOG = 100 MPa = 100 × 106 N/m2 = 100 N/mm2
σOP = 120 MPa = 120 × 106 N/m2 = 120 N/mm2
TP = 15,
and TG = 3TP = 3 × 15 = 45

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 • Machine Design
36 Mechanical Engineering

b = 14 m
σes = 600 MPa = 600 N/mm2
EP = 200 GPa = 200 × 109 N/m2 = 200 × 103 N/mm2
EG = 100 GPa = 100 × 109 N/m2 = 100 × 103 N/mm2
Module:
Let, m = module in mm and
DP = pitch circle diameter of the pinion in mm
πDP NP πmTP NP ⎛ D⎞
Pitch line velocity, V = = ⎜⎝ ∵ m = ⎟⎠
60 60 T
π × m × 15 × 300
= = (235.61 m) mm/s = (0.235 m) m/s
60
Assuming steady load conditions and 8 – 10 hours of service per day, the service factor, Cs is taken as
1. i.e., Cs = 1
We know that the design tangential tooth load,
P 20 × 103 85.10
WT = × Cs = ×1= × 103 N
V 0.235 m m
3 3
and velocity factor, CV = =
3+V 3 + 0.235m
0.912 0.912
Tooth form factor for pinion, yp = 0.154 − = 0.154 − = 0.0932
TP 15
0.912 0.912
And tooth form factor for gear, yG = 0.154 − = 0.154 − = 0.133
TG 45
∴ σOP × yP = 120 × 0.0932 = 11.184
σOG × yG = 100 × 0.133 = 13.3
Since (σOP × yP) is less than (σOG × yG), therefore the pinion is weaker. Now using the Lewis equation to the
pinion, we have,
WT = (σWP bπm yP) = (σOP × CV) bπ myP ( ∵ σWP = σOP × CV)
85.1× 103 ⎛ 3 ⎞
= 120 × ⎜ × (14 m ) × π × m × 0.0932
m ⎝ 3 + 0.235 m ⎟⎠

85.1× 103 1475.69 m 2

=
m (3 + 0.235 m )
57.66 m2
= = 172.98 + 13.55 m = m3
m 3 + 0.235 m
⇒ m3 – 13.55 m – 172.98 = 0
By trial and error method, we get m = 6.37 mm
We can consider the standard module, (of second choice), m = 7
Face width:
Given that face width b = 14 m = 14 × 7 = 98 mm
Pitch diameters of gears:
We know that pitch diameter of the pinion,
DP = mTP = 7 × 15 = 105 mm
Pitch diameter of the gear,

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 Rank Improvement Workbook 37

DG = mTG = 7 × 45 = 315 mm
Checking the gears for wear:

2 × VR 2 × 3
We know that the ratio factor, Q = = = 1.5
VR + 1 3 + 1

(σes )2 sin φ ⎛ 1 1⎞
Load stress factor, K =
1.4 ⎜⎝ E + E ⎟⎠
P G

6002 sin20° ⎛ 1 1 ⎞
= ⎜⎝ + ⎟ = 1.3192 N/mm2
1.4 200 × 103 100 × 103 ⎠
We know that the maximum or limiting load for wear,
WW = DP b QK = 105 × 98 × 1.5 × 1.319 = 20358.765 N
= 20.358 kN
Tangential load on tooth (or beam strength of the tooth)
85.1× 103 85.1× 103
WT = = = 12157.14 N = 12.157 kN
m 7
Since the maximum wear load (20.358 kN) is more than the tangential load (12.157 kN) on the tooth, the
design is satisfactory from the stand point of wear.

Solution : 19
Given, n = 1450 rpm, zp =20, zg = 41
m = 3 mm, b = 40 mm, Cs = 1.75 (fs) = 1.5
BHN = 400, Sut = 600 N/mm2
Step 1: Beam Strength
Since the same material is used for the pinion and the gear, the pinion is weaker than the gear. The
Lewis form factor is 0.32 for 20 teeth.
⎛ 1⎞ ⎛ 1⎞
σb = ⎜ ⎟ Sut = ⎜ ⎟ (600) = 200 N/mm2
⎝ 3⎠ ⎝ 3⎠
Sb = mbσb, Y = 3(40)(200)(0.32) = 7680 N
2zg 2(41)
Step 2: Wear Strength Q = = = 1.344
zg + zp 41 + 20
2 2
⎛ BHN ⎞ ⎛ 400⎞
K = 0.16 ⎜ = 0.16 ⎜ = 2.56
⎝ 100 ⎟⎠ ⎝ 100 ⎟⎠
d ′p = mzp = 3(20) = 60 mm
Sw = bQd ′pK = 40(1.344)(60)(2.56)
= 8257.54 N
3 3
Step 3: Cv = = = 0.397
3 + v 3 + 4.5553
Cs 1.75
Peff = Pt = Pt = (4.41 P1) N
Cv 0.397
Step 4: Static Load
In this example, the beam strength is lower than the wear strength. Therefore, beam strength is the
extension of design.

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 • Machine Design
38 Mechanical Engineering

Sb = Peff (fs) P1 7680 = (4.41 P1)(1.5)

Pr = 1161 N
Step 5: Rated Powder
P1d p′ 1161(60)
M = = = 34.830 N-mm
2 2
2πnpMt 2π(1450)(34.830)
kW = 6 = = 5.29
60 × 10 60 × 106
Solution : 20
Given: TP = 18 teeths; TG = 45 teeths; m = 10 mm; dP = 180 mm; dG = 450 mm; φ = 20°
1
Centre distance, C = R+r= (180 + 450) = 315 mm
2
But actual centre distance, C ′ = C + 8 mm = 315 + 8 = 323 mm
Assuming the teeth profile as involute, the centre distance variation will not alter the velocity ratio.
dG dG ′ 450
VR = = = = 2.5
dP dP ′ 180
dG′ = 2.5 dP′
1
and C′ = (d ′ + dG ′)
2 P
1
323 = (d ′ + 2.5dP ′)
2 P
New pitch circle diameter, dP′ = 184.5 mm
and dG′ = 2.5 × 184.5 = 461.42 mm
Also, the base circle radius remains unaltered. Let φ′ be the new increased pressure cycle.
R ′cosφ′ = R cos φ
230.71 cos φ′ = 225 cos20°
φ′ = cos–1 (0.9164) = 23.6°
Power transmitted, P = 20 kW
N P = 950 rpm
60 × P 60 × 20 × 103
Torque, T = = = 201.14 N-m
2 πN p 2 × π × 950
Ft = tangential force
T = Ft × rP′
201.14 × 103
Ft = = 2180.4 N
92.25
Fr = radial load
Ft tanφ′ = 2180.4 tan 23.6°
Fr = 952.6 N
and normal tooth load
Ft 2180.4
FN = = = 2379.4 N
cos φ′ cos23.6

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 Rank Improvement Workbook 39

Solution : 21
Given data: φ = 20°; TP = 24 tooth; NP = 950 rpm; TG = 60 tooth; m = 6 mm; b = 60 mm;
σy = 330 N/mm2; σu = 680 N/mm2; σe′ = 0.55 σu = 0.55 × 680 = 374 N/mm2
Co = overload factor = 1.8
Surface endurance limit = 1500 MPa
Dynamic factor, Cv = 2.5
(i) Beam strength = σb b m π y
when pinion and shaft are of same material, pinion is made weaker
dp = mTp = 6 × 24 = 144 mm
πd pNP π × (0.144) × 950
V = = = 7.1592 m/sec
60 60
0.912 0.912
for 20° full depth, y = 0.154 − = 0.154 − = 0.116
TP 24

⎛ 680 ⎞
× 60 × π × 6 × 0.116
σb ⋅ bm πy ⎜⎝ 3 ⎟⎠
Beam strength Pb = =
CoCv 1.8 × 2.5
= 6604.88 N
(ii) Wear strength Pw = dp K Q b
2VR 2TG 2 × 60
Q = = = = 1.428
VR + 1 TG + TP 60 + 24

(σe )2 sin φ ⎡ 1 1 ⎤ (1500)2 × sin20° ⎡ 1 ⎤

K = ⎢ + ⎥ = ⎢ × 2⎥
1.4 ⎣ E p EG ⎦ 1.4 ⎣ 2.1 × 10 5
⎦
= 5.235 MPa
Pw = (24 × 6) × 5.235 × 1.428 × 60
= 64589
Pb 6604.88
(iii) Rated power = Peff × V = = = 2641.952 N
FOS 2.5
Power = 2641.952 × 7.1592 = 18.92 kW

Solution : 22
Let m = required module
TP = number of teeth on the pinion
TG = number of teeth on the gear
DP = PCD of the pinion
DG = PCD of the gear
Minimum number of the teeth on the pinion to avoid interference:
2A w
TP =
⎡ 1⎛ 1 ⎞ ⎤
G ⎢ 1+ ⎜⎝ + 2⎟⎠ sin2 φ − 1⎥
⎣ G G ⎦
2 ×1
TP =
10 ⎡⎣ 1 + 0.1 × 2.1 × sin2 22.5° − 1⎤⎦

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 • Machine Design
40 Mechanical Engineering

TP = 13.3 say 14
TG = G × TP = 10 × 14 = 140 mm
DP + DG ⎛ 10 + 1⎞
=⎜ D = 5.5 DP
Centre distance, C =
2 ⎝ 2 ⎟⎠ P
or 660 = 5.5 DP
6600
DP = = 120 mm
55
DP = m × TP
120
m = = 8.6 mm
14
Nearest standard value of module,
m = 8 mm Ans. (i)
Number of teeth on the pinion,
DP 120
TP = = = 15 Ans(ii)
m 8
Number of teeth on the gear,
TG = 10 × 15 = 150 mm Ans(iii)

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 7 Bearings

1. (d)
16. (a)
2. (c)
17. ∗)
(∗
3. (b)
18. (10.22)
4. (d)
19. (a)
5. (a)
20. (157.46)
6. (b)
21. (3.55)
7. (d)
22. (d)
8. (c)
23. (4.4)
9. (c)
24. (b)
10. (a)
25. (21.78)
11. (a)
26. (64.45)
12. (d)
27. (c)
13. (c)
28. (c)
14. (d)
29. (b)
15. (b) „„„„

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 • Machine Design
42 Mechanical Engineering

Solution : 30
Given journal diameter, D = 60 mm, ⇒ r = 30 mm
Bearing length, L = 60 mm, L/D = 1
Radial load, W = 2.8 kN
Journal speed, N = 1020 rpm

1020
ns = rps
60
Radial clearance, C = 0.05 mm
Viscosity of oil, r = 80 × 10–9 N-s/mm2
2
⎛ r ⎞ μns
(i) Sommerfeld number S = ⎜ ⎟
⎝ c⎠ p

W 2.8 × 103N
Bearing pressure P = = = 0.78 N/mm2
LD 60 × 60
⎛ 1020 ⎞
(80 × 10 −9 ) × ⎜
⎝ 60 ⎟⎠
2
S = ⎛⎜
30 ⎞
∴ ⎟ × = 0.627  0.630
⎝ 0.05 ⎠ 0.78
From the given table,
⎛r⎞
for the value of S = 0.630, ⎜ ⎟ f = 12.8
⎝c⎠
h0
= 0.8, and
c
Q
= 3.59
rcns l

⎛r⎞ Q
where coefficient of friction variable C.F.V. = ⎜ ⎟ f and flow variable F.V. =
⎝c⎠ rcns l
⎛r⎞
⎜⎝ ⎟⎠ f = 3.22
c
c 0.05
Coefficient of friction f = 12.8 × = 12.8 × = 0.0213
r 30
(ii) Power loss in friction, (kW)
⎛ 1020 ⎞
2π × ⎜ × 0.0213 × 2.8 × 103 × 30
2πnsfwr ⎝ 60 ⎟⎠
= =
106 106
= 0.1911 kW
h0
= 0.8, h0 = 0.8 × c = 0.8 × 0.05 = 0.04 mm
c
Q
= 3.59 = FV
rcns l

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 Rank Improvement Workbook 43

(iii) We know temperature rise,

8.3 × p × (CFV ) 8.3 × 0.78 × 12.80
ΔT = = = 23.082°C
(FV ) 3.59
h0
(iv) From the table for = 0.8, S = 0.630
c
we get φ = 74.02° i.e., angle of eccentricity (or location)
h0
= 0.8
c
Minimum film thickness
h0 = 0.8 × c = 0.8 0 × 0.05 = 0.04 mm = 40 microns

Solution : 31
l ⎛C⎞ h
Given: = 1, w = 1.1 kN, μ = 55.2 × 10–3 Pa.s, ns = 18.33 rps, f = 4 ⎜ ⎟ , o = 0.58
D ⎝r⎠ C
Hole limit 25.038 mm
Shaft limit 25 mm
25.038 − 25
Radial clearance, C = = 0.019 mm
2
2
⎛ r ⎞ μns
(a) Sommerfield number = ⎜ ⎟
⎝ C⎠ P
Where, μ is in MPa.s
P is in N/mm2 or MPa
ns is in rps
w 1.1× 103
P = = = 1.76 N/ mm2
lD 25 × 25
2
⎛ 12.5 ⎞ 55.2 × 10−9 × 18.33
∴ S = ⎜ ⎟ × = 0.2488
⎝ 0.019⎠ 1.76 × 106
ho
(b) = 0.58
C
∴ ho = 0.58 × 0.019 = 0.0110 mm
⎛C⎞ 0.019
(c) f = 4⎜ ⎟ = 4 × = 0.006
⎝r⎠ 12.5
Frictional force = 0.006 × 1100 = 6.088 N
25
Frictional torque = 6.688 × = 83.6 N- mm Ans.
2

Solution : 32
A ball bearing operates on the given work cycle as:
Considering the work cycle of one minute duration. Then,
N1 = 0.3 × 1440 = 432 revolutions
N 2 = 0.35 × 750 = 262.5 revolutions
N3 = 0.35 × 1440 = 504 revolutions

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 • Machine Design
44 Mechanical Engineering

P 3N + P23N2 + P33N3
3 1 1
∴ Equivalent load, Pe =
N1 + N2 + N3

3 432 × (3500)3 + 262.5 × (6000)3 + 504 × (2500)3

=
432 + 262.5 + 504
Pe = 4108.18 N
Bearing life = 10,000 hours
60 × (432 + 262.5 + 504) × 10,000
L10 = = 719.1 million rev.
106
Let C be its dynamic load carrying capacity
3
⎛ C⎞
L10 = ⎜
⎝ Peq ⎟⎠
3
⎛ C ⎞
719.1 = ⎜
⎝ 4108.18 ⎟⎠
C = 36.8 kN
Solution : 33
Given: C = 26 kN, L10h = 8000 hr, n = 300 rpm
Step I: Bearing life (L10)
60nL10h 60(300)(8000)
L10 = 6
= = 144 million rev.
10 106
Step II: Equivalent radial load
C = P(L10)0.3;
C 26000
∴ P = = = 5854.16 N
(L10 ) (144)0.3
Since the bearing is subjected to purely radial load ,
Fr = P = 5854.16 N

Solution : 34
50 mm

50 mm
3.2 kN

3200
Bearing pressure P = = 1.28 N/mm2 = 1.28 × 106 N/m2
d⋅ l
(i) Sommerfield No
1500
⎛ μ Ns ⎞⎛ r ⎞
2 0.025 × 2
60 ⎛ 25 ⎞ = 0.122
S = ⎜ ⎟ ⎜C⎟ = ⎜ ⎟
⎝ P ⎠⎝ ⎠ 1.28 × 106 ⎝ 0.05 ⎠
(ii) Ploss = Friction torque × ω = f × load × r × ω
2π
= 0.00322 × 3200 × 0.025 × × 1500 = 40.46 watt
60

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 Rank Improvement Workbook 45

h0
(iii) ∈ = 1−
C
e h
= 1− 0
C C
h0 e 0.03
= 1− = 1− = 1 – 0.6 = 0.4
C C 0.05
h0 = 0.4 × 0.05 = 0.02 mm
μ Ns 0.025 × 25
(iv) Bearing modulus = = = 0.4883 × 10–6
P 1.28 × 106
Solution : 35

75 mm lies in the diameter steps of 50 to 80 mm, so

D = 50 × 80 = 63 mm
Standard tolerance unit, i = 0.45 3 D + 0.001D = 0.45(63)1/3 + 0.001 × 63
= 1.79 + 0.063 = 1.853 miron
Standard tolerance for hole = 25 i = 25 × 1.853 × 10–3 = 0.046 mm
Standard tolerance for shaft = 16 i = 16 × 1.853 × 10–3 = 0.03 mm
(ii) Length = Diameter = 90 mm
Speed, N = 450 rpm
Viscosity, Z = 0.06 kg/ms
Diametral clearance, C = 0.1 mm
Sommerfeld number = 14.3 × 106
2
ZN ⎛ d ⎞
⎜ ⎟ = 14.3 × 106
P ⎝ c⎠
2
0.06 × 450 ⎛ 90 ⎞
or ⎜⎝ ⎟⎠ = 14.3 × 106
P 0.1
P = 1.53 N/mm2
Safe bearing load, W = Pressure x Projected Area
W = 1.53 × 90 × 90 = 12393 N

Solution : 36
Journal diameter d = 50 mm = 0.05 m
length of journal, l = 100 mm = 0.1 m
Bearing pressure, p = 1.4 N/mm2
Viscosity at 75°C, Z = 0.011 kg/ms
Operating temperature, ta = 35°C
Specific heat, Cp = 1850 J/kg/°C
33 ⎛ ZN ⎞ ⎛ d ⎞
Coefficient of friction, μ = ⎜ ⎟⎜ ⎟ + k
108 ⎝ P ⎠ ⎝ c ⎠
33 ⎛ 0.011× 900 ⎞
μ = ⎜ ⎟ × 1000 + 0.002
108 ⎝ 1.4 ⎠
μ = 0.00233 + 0.002 = 0.00433

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 • Machine Design
46 Mechanical Engineering

Load on the bearing, W = p × d l = 1.4 × 50 × 100

W = 7000 N

πdN 3.14 × 0.05 × 900

Rubbing velocity, V = = = 2.36 m/s
60 60
Heat generated, Qg = μWV = 0.00433 × 7000 × 2.36
Qg = 71.5 J/s
Temperature of the bearing surface = tb
1 75.35
tb – ba = (t 0 − ta ) = = 20°C
2 2
Heat dissipated, Qd = hA(tb – ta)
Qd = 280 × 0.05 × 0.1 × 20(20)
Qd = 28 J/s
∴ Amount of artificial cooling required
= Qg – Qd = 71.5 – 28 = 43.5 W
Let, m = mass of the lubricating oil required in kg/s
∴ Qg = Qt

71.5
m = = 0.00386 kg/s = 0.23 kg/min
18500
„„„„

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 8 Shafts

1. (c) 11. (d)

2. (d) 12. (d)

3. (b) 13. (a)

4. (d) 14. (a)

5. (c) 15. (d)

6. (a) 16. (1280)

7. (b) 17. (d)

8. (c) 18. (30)

9. (d) 19. (d)

10. (26.89) „„„„

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 • Machine Design
48 Mechanical Engineering

Solution : 20
Given
For pulley, T1 = 3T2
For gear, pressure angle , φ = 20°
D2 = 300 mm
A Pr
power, P = 20 kW
Pt
N = 500 rpm
B
P 20 × 103 400 C
Torque transmitted, T = = 400
ω ⎛ 2π × 500 ⎞
⎜⎝ ⎟
60 ⎠ 400
D
20 × 103
= = 381.97 N-m
52.36
= 381971 N-mm
The same torque applies for pulley
P2 P1
i.e. (T1 – T2)225 = 381971 = T1 – T2 = 1697.65 N
⇒ 3T2 – T2 = 1697.65 ( ∵ T1 = 3T2 )
⇒ T2 = 848.83N
T1 = 2546.48 N
= T1 + T2 = 3395.31 N
For the gear, torque T = Ft × 150, Ft → Tangential force (horizontal)
381971 = Ft × 150
⇒ Ft = 2546.48 N
Fr = Ft × tan 20°, Ft → Radial force (vertical)
= 2546.48 × tan 20° = 926.84 N
Invertical plane: 1234.24N 926.84N 3395.31N
RAV + RCV = 926.84 + 3395.31
= 4322.15 N C
A B D
ΣMA = 0
0.4 m 0.4 m 0.4 m
RCV × 0.8 = 926.84 × 0.4 + 3395.31 × 1.2 5556.38N
RCV = 5556.38 N (upwards)
⇒ RAV = 4322.15 – 5556.38
= 1234.24 N (downwards) i.e. – 1234.24 N
BMB = –1234.24 × 0.4 = –493.696 N-m B C D
A
BMC = 3395.31 × 0.4
= 1358.124 N-m
In horizontal plane: 493.696 N-m
RAH + RCH = 2546.48, RDH = 0
1358.124 N-m
2546.48
RAH = RCH = = 1273.24 N
2

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 Rank Improvement Workbook 49

2546.48N

A C D
B

1273.24N 1273.24N

BMB = 1273.24 × 0.4 = 509.296 N-m

The maximum B.M is at point C, 509.296 N-m

i.e. MC = 1358.124 N-m

and maximum torque, T = 381.971 N-m

Equivalent torque, Te = (kbM )2 + (kcT )2

A B C

= (1.5 × 1358.124)2 + (1.5 × 381.971)2

Te = 2116.224 N-m [∵ kb = kt = 1.5 (given)]
mostly shafts are designed on the basis of maximum shear stress theory,
given tensile strength of the shaft and key is 700 MPa.
= 700 × 106 N/m2
Allowance for the key way for stress as 0.75 and factor of safety = 5
0.75 × 700 × 106
∴ τ = = 52.5 × 106
5
16Te 16 × 2116.224
∴ 52.5 × 106 = = (∵ τ = 16 T/πd3)
πd 3
π × d3
d = 0.05899 m = 58.99 mm (diameter of the shaft)
 60 mm
maximum shear stress for the key
σ 700
τ= × 0.75 = × 0.75 = 52.5 N/mm2
2 × F .S 2×5
d
For the key, take width w = thickness, t =
4
60
w= t= = 15 mm
4
d
∴ Torque T = τ× lw (for crushing)
2
60
= 381971 N-m = 52.5 × × l × 15
2
⇒ l = 16.16 mm

Solution : 21
6.8 kN
75 75
300 200 D
A B C
30 50 E 35
A B C D
All dimension in mm

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 • Machine Design
50 Mechanical Engineering

Let RA and RD be the reaction forces Mmax

RA + RD = 6.8 kN
MB MC
and RD × 650 = 6.8 × 375

RD = 3.923 kN

and RA = 2.877 kN A B E C D

MB = Bending moment at section BB

= RA × 300 = 863.1 N-m
ME = RA × (375) = 1078.875 N.m
and MC = RD × 200 = 784.6 N.m
Thus critical section can be B, C and E.
32MB 32 × 863.1× 103
σB = = = 325.77 MPa
πd 3 π(30)3
32ME 32 × 1078.875 × 103
σE = = = 87.95 MPa
πd 3 π(50)3
32MC 32 × 784.6 × 103
σC = = = 186.5 MPa
πd 3 π(35)3
(Kt )B = 1.5 and (Kt)C = 1.4
(σmax)B = 1.5 × 325.77 = 488.65 MPa
(σmax)C = 1.4 × 186.5 = 261.1 MPa
Hence, section B-B is the most critical section among B, E and C.
Kf − 1
Also, q =
Kt − 1
(Kf )B = 0.95 × (1.5 – 1) + 1 = 1.475
1 1
Kd = = = 0.6779
Kf 1.475
Se = Cr × Kd × Se′
and Se ′ = 0.55 × σu = 0.55 × 650 = 375.5 N/mm2
Se = 0.897 × 0.6779 × 357.5 = 217.38 N/mm2
(σmax )B 488.65
Therefore, FOS = = = 2.25
Se 217.38
Solution : 22
Let d as ammeter of shaft in mm
π 3
Section modulus of shaft, Z = d = 0.0982 d 3 mm3
32
Tensile stress due to bending moment,
M 10 × 106 101.8 × 106
σ = = = N / mm2
Z 0.0982 d 3 d 3

shear stress due to torsional moment,

16T 16 × 30 × 106 152.8 × 106
τ = = = N / mm2
πd 3 3.14 × d 3 d3

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 Rank Improvement Workbook 51

Maximum principal stress,

σ 1 2
σ1 = + σ + 4 τ2
2 2
⎡ 2 2⎤
101.8 × 102 1 ⎢ ⎛ 101.8 × 106 ⎞ ⎛ 152.3 × 106 ⎞ ⎥
σ1 = + ⎜ +
⎟⎟ ⎜⎜ ⎟⎟ ⎥
4
2d 3 2 ⎢ ⎜⎝ d3 ⎠ ⎝ d3 ⎠ ⎥
⎣⎢ ⎦
50.9 × 106 106
σ1 = 3
+ 3
(101.8)2 + 4(152.8)2
d 2d
6
50.9 × 10 161 + 106 211.9 × 106
σ1 = 3
+ 3
= 3
N / mm2
d d d
According to maximum strain energy theory,
2
⎛ σy ⎞
σ1 2+ σ22 – 2νσ1σ2= ⎜ ⎟
⎝N ⎠
2 2
⎛ 211.9 × 106 ⎞ ⎛ 110.1× 106 ⎞ ⎛ 211.9 × 106 ⎞ ⎛ 110. × 106 ⎞
or ⎜⎜ ⎟ + ⎜ ⎟ + 0.5 ⎜⎜ ⎟⎟ ⎜⎜ ⎟⎟ = (350)2
d 3 ⎟ ⎜ d 3 ⎟ d 3
d 3
⎝ ⎠ ⎝ ⎠ ⎝ ⎠⎝ ⎠
44902 × 1012 12122 × 1012 11665 × 1012
or + + = 122500
d6 d6 d6
68689 × 1012
or = 122500
d6
or d 6 = 0.5607 × 1012
or d = 90.8 mm
Solution : 23
Torque, T = 5400 Nm = 5400 × 103 Nmm
Allowable stress, τall = 150 MPa
Tc
τ =
J
5400 × d /2 40230
⇒ 150 × 106 = =
π ⎡ 4 d3
d − (0.75d ) ⎤⎦
4
32 ⎣
40230
d3 = = 2.682 × 10−4
150 × 106
d = 6.45 × 10 –2 m or 64.5 mm
The next preferred size is d = 80 mm
Outer diameter = 80 mm
Inner diameter = 60 mm Ans. (i)
π ( 4
J = 80 − 604 ) = 2.749 × 106 mm4
32
5400 × 103 × 60
shear stress, τ = = 58.9 MPa Ans. (ii)
2 × 2.749 × 106

„„„„

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