Machine Design Answer Key

Hindusthan College of Engineering and
Technology
(An Autonomous Institution, Affiliated to Anna University, Chennai)
Valley Campus, Pollachi Highway, Coimbatore – 641032
Department : MECHATRONICS ENGINEERING

Course Code & Name: 21MT5201-MACHINE DESIGN
Semester: V
ANSWER KEY
Part A – (10 X 2 = 20 Marks)
1. List out the factors to consider the selection of factor of safety.
Material, mode of manufacture, type of stress, general service conditions and shape of the parts.
2. Differentiate between repeated stress and reversed stress
Repeated stress refers to a stress varying from zero to a maximum value of same nature. Reversed stress
of cyclic stress varies from one value of tension to the same value of compression.
3. Why a hollow shaft has greater strength and stiffness than solid shaft of equal weight?
A hollow shaft is found to be stronger than a solid shaft made of equal material because the torque
required to produce a given twist in hollow cylinder is greater than that required to produce in solid
cylinder of same length and material through same angle.
4. Name the welding methods.
1) arc welding, 2) resistance welding, 3) oxy-fuel gas welding, and 4) other fusion welding processes
5. Illustrate the materials for making gears.
Gears can be made of all sorts of materials, including many types of steel, brass, bronze, cast iron, ductile
iron, aluminum, powdered metals, and plastics.
6. Identify at what occasions nonmetallic gears are employed.
Non-metallic gears are employed 'where we require silent operation and low power transmission.
7. In what ways the clutches are different from brakes.
A clutch is a transmission and control device that provides for energy transfer from the driver to the
driven shaft. A brake is a transmission and control device that stops a moving load, regulates movement,
or holds a load at rest by transforming kinetic energy into heat.
8. Write the features of a chain drives.
Chain drives are a fundamental and versatile method of power transmission widely employed in various
mechanical systems. They consist of a flexible looped chain that meshes with sprockets to transfer
rotational motion and power from one component to another.
9. Classify the types of bearings.
Bearings are divided into two basic categories: (1) rolling element or "anti-friction" bearings, (2) sliding
surface or "plain" bearings.
10. Select some of the material used for springs.
Most springs are metal from some type of steel alloy.
Part B – (5 X 14 = 70 Marks)
11. The load on a bolt consists of an axial pull of 10 kN together with a transverse shear force of 5
kN. Find the diameter of bolt required according to 1. Maximum principal stress theory; 2.
Maximum shear stress theory; 3. Maximum principal strain theory; 4. Maximum strain energy
theory; and 5. Maximum distortion energy theory.
12. A steel bar is subjected to a reversed axial load of 180 kN. Find the diameter of the rod for a
factor of safety of 2. Neglect column action. The material has an ultimate tensile strength of
1070 MPa and yield strength of 910 MPa. The endurance limit in reversed bending may be
assumed to be one-half of the ultimate tensile strength. Other correction factors may be taken
as follows: For axial loading = 0.7; For machined surface = 0.8 ; For size = 0.85 ; For stress
concentration = 1.0
13. Design a shaft to transmit power from an electric motor to a lathe head stock through a pulley
by means of a belt drive. The pulley weighs 200 N and is located at 300 mm from the centre of
the bearing. The diameter of the pulley is 200 mm and the maximum power transmitted is 1 kW
at 120 r.p.m. The angle of lap of the belt is 180° and coefficient of friction between the belt and
the pulley is 0.3. The shock and fatigue factors for bending and twisting are 1.5 and 2.0
respectively. The allowable shear stress in the shaft may be taken as 35 MPa.13.
Given : W = 200 N ; L = 300 mm ; D = 200 mm or R = 100 mm ; P = 1 kW = 1000 W ; N = 120 r.p.m. ; θ

= 180° = π rad ; μ = 0.3 ; Km = 1.5 ; Kt = 2 ; τ = 35 MPa = 35 N/mm2
14. A rectangular steel plate 100mm wide is welded to a vertical plane to form a cantilever with an
overlap of 50mm and an overhang of 150mm. It carries a vertical downward load of 60KN at
free end.Fillet weld is done three sides of the plate for a permissible stress is 140 N/mm2.
Determine the size of the weld.
15. Design a straight spur gear drive to transmit 8Kw. The pinion speed is 720 rpm and the speed
ratio is 2. Both the gears are made of the same surface hardened carbon steel with 55RC and
core hardness less than 350 BHN.Ultimate strength is 720N/mm2 and yield strength is 360
N/mm2.
16. Design a pair of helical gear to transmit 30kw power at a speed reduction ratio of 4:1. The input
shaft rotates at 2000 rpm. Take helix and pressure angles equal to 250 and 200 respectively. The
number of teeth on the pinion may be taken as 30.
17. A rope drum of an elevator having 650 mm diameter is fitted with a brake drum of 1 m
diameter. The brake drum is provided with four cast iron brake shoes each subtending an angle
of 45°. The mass of the elevator when loaded is 2000 kg and moves with a speed of 2.5 m / s. The
brake has a sufficient capacity to stop the elevator in 2.75 metres. Assuming the coefficient of
friction between the brake drum and shoes as 0.2, find: 1. width of the shoe, if the allowable
pressure on the brake shoe is limited to 0.3 N/mm2; and 2. heat generated in stopping the
elevator.
18. Select a chain drive to actuate a compressor from 15 kW electric motor running at 1000 r.p.m.,
the compressor speed being 350 r.p.m. The minimum centre distance is 500 mm. The
compressor operates 16 hours per day. The chain tension may be adjusted by shifting the motor
on slides.
19. Select a bearing for a 45mm diameter shaft rotates at 500 rpm. Due to a bevel gear mounted on
the shaft, the bearing will have to withstand a 4500 N radial load and a 2500N thrust load. The
life of the bearing expected to be least 6000hr.
20. A leaf spring for a small trailer is to support a load of 10KN. The spring has 6 graduated leaves
and 2 extra full length leaves of spring steel of safe stress 360 Mpa. The overall length is 1.2m
and the central band is wide. Taking the ratio of total depth of leaves to width as 3, design the
spring.
PART – C (1 X 10 = 10)
21. a) a helical spring is subjected to a load varying from 450N to 1050N having spring index of 6
and the design factor of safety is 1.2. the compression of the spring at the maximum load is 30mm.
Design the helical compression spring. Take yield stress inn shear as 120N/mm2 endurance stress in
shear as 360N/mm2 and the modulus of rigidity for the spring material as 75*103 N/mm2.
21.b) Design a pair of bevel gears for two shafts whose axes are at right angles. The power
transmitted is 25KW. The speed of the pininon is 300 rpm and the gear is 120rpm.
 Calculation of gear ratio from psg data book pg 8.6

 Selection of materials. from psg data book pg 1.40
 Selection of gear life based on given data.
 Calculation of initial design torque from psg data book pg 8.15. table no13
 Determination of equivalent young’s modulus from psg data book pg8.14. table no.9
 Calculation of design contact stress from psg data book pg 8.16. table no.15
 Calculation of design of bending stress from psg data book pg 8.18.
 Calculation of cone distance from psg data book pg8.13. table no.8
 Selection of Z1 and Z2 assume Z1 initially as ≥17.
 Calculation for transverse module psg data book pg8.38 table no31.
 Revision of cone distance psg data book pg8.38 table no.31.
 Calculation of face width from psg data book pg8.15 table no. 13
 Calculation of reference diameter from psg data book pg8.38 table no. 31.
 Selection of quality of gear from psg data book pg8.3 table no. 2
 Revision of design torque from psg data book pg8.15 16.Check for contact stress from psg data book
pg8.13
 Check for bending stress from psg data book pg8.13 A

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Hindusthan College of Engineering and

Department : MECHATRONICS ENGINEERING

1. List out the factors to consider the selection of factor of safety.

2. Differentiate between repeated stress and reversed stress

4. Name the welding methods.

5. Illustrate the materials for making gears.

6. Identify at what occasions nonmetallic gears are employed.

8. Write the features of a chain drives.

9. Classify the types of bearings.

10. Select some of the material used for springs.

Most springs are metal from some type of steel alloy.

Given : W = 200 N ; L = 300 mm ; D = 200 mm or R = 100 mm ; P = 1 kW = 1000 W ; N = 120 r.p.m. ; θ

 Calculation of gear ratio from psg data book pg 8.6

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