Register No.

BE/B.Tech Degree Examination , May 2024

Sixth Semester

20MET63 – DESIGN OF MACHINE ELEMENTS

(Regulations 2020)

Time : Three hours Maximum : 100 Marks

Answer all Questions

PART – A (10 X 2 = 20 Marks)

1. List any four factors influencing machine design [CO1,K1]

2. Draw Goodman and Soderberg line and locate safe design region [CO1,K2]
3. Differentiate shaft and axle [CO2,K2]
4. What is a self actuating or self energizing brake? When a brake becomes a self locking? [CO2,K2]
5. Write any four advantages of bolted joints [CO3,K2]
6. Name the stresses induced in welded joints. [CO3,K2]
7. What do you meant by nipping in springs? [CO4,K2]
8. List out the required qualities of a good friction materials used in clutches. [CO4,K2]
9. State the meaning of L10 life of a bearing [CO5,K2]
10. Define coefficient of fluctuation of speed. [CO5,K2]

PART – B (5 X 16 = 80 Marks)
11. a. i) A wall bracket with a rectangular cross-section is shown in Fig. The depth of the cross- [CO1,K3]
section is twice of the width. The force P acting on the bracket at 60° to the vertical is 8 kN.
The material of the bracket is grey cast iron FG 200 and the factor of safety is 2.5.
Determine the dimensions of the cross-section of the bracket. Assume maximum normal
stress theory of failure.

ii) The frame of a hacksaw is shown in Fig. 4.26(a). The initial tension P in the blade should
be 320 N. The frame is made of plain carbon steel 30C8 with tensile yield strength of 440
N/mm2 and the factor of safety is 3.5. The cross section of the frame is rectangular with a
ratio of depth to width as 4, as shown in Fig. Determine the dimensions of the cross-
section.
 (Or)
11. b. i) A cantilever beam made of cold drawn steel 4OC8 (Sut = 560 N/mm2 and S yt = 280 [CO1,K3]
N/mm2) is shown in Fig. The force P acting at the free end varies from –50 N to +150 N.
The expected reliability is 90% and the factor of safety is 2.8. The notch sensitivity factor at
the fillet is 0.8. Determine the diameter d of the beam at the fillet cross-section using Gerber
curve as failure criterion.

ii). A rotating bar made of steel 45C8 (Sut = 530 N/mm2) is subjected to a completely
reversed bending stress. The corrected endurance limit of the bar is 215 N/mm 2. Calculate
the fatigue strength of the bar for a life of 91,010 cycles.

12. a. i) The layout of a transmission shaft carrying two pulleys B and C and supported on [CO2,K3]
bearings A and D is shown in Fig. Power is supplied to the shaft by means of a vertical belt
on the pulley B, which is then transmitted to the pulley C carrying a horizontal belt. The
maximum tension in the belt on the pulley B is 3.5 kN. The angle of wrap for both the
pulleys is 180° and the coefficient of friction is 0.34. The shaft is made of plain carbon steel
30C8 (Syt = 444 N/mm2) and the factor of safety is 3. Determine the shaft diameter on
strength basis.

ii) The dimensions of a Woodruff key for a 30 mm diameter shaft are shown in Fig. The
shaft is transmitting 5.5 kW power at 323 rpm The key is made of steel 50C4 ( S yt = Syc= 531
N/mm2). Calculate the factor of safety used in design.

(Or)
12. b. i) A four-wheeled automobile car has a total mass of 1030 kg. The moment of inertia of [CO2,K3]
each wheel about a transverse axis through its centre of gravity is 0.6 kg-m 2. The rolling
radius of the wheel is 0.35 m. The rotating and reciprocating parts of the engine and the
transmission system are equivalent to a moment of inertia of 3.5 kg-m 2, which rotates at
five times the road-wheel speed. The car is traveling at a speed of 120 km/h on a plane
road. When the brakes are applied, the car decelerates at 0.56 g. There are brakes on all
four wheels. Calculate:
(a) the energy absorbed by each brake; and
 (b) the torque capacity of each brake.

ii) A single block brake with a torque capacity of 255 N-m is shown in Fig. The brake drum
rotates at 111 rpm and the coefficient of friction is 0.39. Calculate
(a) the actuating force and the hinge-pin reaction for clockwise rotation of the drum;
(b) the actuating force and hinge-pin reaction for anticlockwise rotation of the drum;
(c) the rate of heat generated during the braking action; and
(d) the dimensions of the block, if the intensity of pressure between the block and brake
drum is 1 N/mm2. The length of the block is twice its width.
State whether the brake is self-locking.

13. a. i) A steel plate subjected to a force of 5.6 kN and fixed to a channel by means of three [CO3,K3]
identical bolts is shown in Fig. The bolts are made from plain carbon steel 45C8 (S yt =
280N/mm2) and the factor of safety is 3.6. Specify the size of bolts.

ii) A wall bracket is attached to the wall by means of four identical bolts, two at A and two
at B, as shown in Fig. Assuming that the bracket is held against the wall and prevented
from tipping about the point C by all four bolts and using an allowable tensile stress in the
bolts as 46 N/mm2, determine the size of the bolts on the basis of maximum principal
stress theory.

(Or)
13. b. i) A plate, 75 mm wide and 13 mm thick, is joined with another steel plate by means of [CO3,K3]
single transverse and double parallel fillet welds, as shown in Fig. The joint is subjected to
a maximum tensile force of 65 kN. The permissible tensile and shear stresses in the weld
material are 72 and 56 N/mm2 respectively. Determine the required length of each parallel
fillet weld.
 ii) A bracket is welded to the vertical column by means of two fillet welds as shown in Fig.
Determine the size of the welds, if the permissible shear stress in the weld is limited to 57
N/mm2.

14. a. i) A helical compression spring, made of circular wire, is subjected to an axial force, which [CO4,K3]
varies from 3.5 kN to 4.5 kN. Over this range of force, the deflection of the spring should be
approximately 5 mm. The spring index can be taken as 5. The spring has square and
ground ends. The spring is made of patented and cold-drawn steel wire with ultimate
tensile strength of 1555 N/mm2 and modulus of rigidity of 81850 N/mm 2. The permissible
shear stress for the spring wire should be taken as 50% of the ultimate tensile strength.
Design the spring and calculate
(a) wire diameter; (b) mean coil diameter; (c) number of active coils; (d) total number of
coils;
(e) solid length of the spring; (f) free length of the spring; (g) required spring rate; and
(h) actual spring rate

ii) A semi-elliptic leaf spring used for automobile suspension consists of three extra full-
length leaves and 18 graduated-length leaves, including the master leaf. The centre-to-
centre distance between two eyes of the spring is 1.5 m. The maximum force that can act on
the spring is 75 kN. For each leaf, the ratio of width to thickness is 7:1. The modulus of
elasticity of the leaf material is 205 000 N/mm 2. The leaves are pre-stressed in such a way
that when the force is maximum, the stresses induced in all leaves are same and equal to
410 N/mm2.
Determine
(a) the width and thickness of the leaves; (b) the initial nip; and (c) the initial pre-load
required to close the gap C between extra full-length leaves and graduated-length leaves.
(Or)
14 b. i) A single plate clutch consists of only one pair of contacting surfaces. It is used for an [CO4,K3]
engine, which develops a maximum torque of 95 N-m. Assume a factor of safety of 3.5 to
account for slippage at full-engine torque. The permissible intensity of pressure is 450 kPa
and the coefficient of friction is 0.53. Assuming uniform wear theory, calculate the inner
and outer diameters of the friction lining.

ii) A cone clutch with asbestos friction lining transmits 33 kW power at 430 rpm. The
coefficient of friction is 0.4 and the permissible intensity of pressure is 0.22 N/mm 2. The
semi-cone angle α is 12.5°. The outer diameter is fixed as 300 mm from space limitations.
Assuming uniform wear theory, calculate:
(a) the inner diameter; (b) the face width of the friction lining; and (c) the force required to
 engage the clutch.

15 a. i) A single-row deep groove ball bearing has a dynamic load capacity of 42800 N and [CO5,K3]
operates on the following work cycle:
(a) radial load of 3500 N at 500 rpm for 25% of the time;
(b) radial load of 9600 N at 700 rpm for 50% of the time; and
(c) radial load of 4030 N at 400 rpm for the remaining 25% of the time.
Calculate the expected life of the bearing in hours.

ii) The following data is given for a hydrostatic thrust bearing:

thrust load = 660 kN
shaft speed = 852 rpm
shaft diameter = 620 mm
recess diameter = 350 mm
film thickness = 0.12 mm
viscosity of lubricant = 140 SUS
specific gravity = 0.82
Calculate
(a) supply pressure;
(b) flow requirement in litres/min;
(c) power loss in pumping; and
(d) frictional power loss.
(Or)
b. i) A machine is driven by a motor, which exerts a constant torque. The resisting torque of [CO5,K3]
the machine increases uniformly from 510 N-m to 1800 N-m through a 360° rotation of the
driving shaft and drops suddenly to 510 N-m again at the beginning of the next revolution.
The mean angular velocity of the machine is 30 rad/s and the coefficient of speed
fluctuations is 0.22. A solid circular steel disk, 45 mm thick, is used as flywheel. The mass
density of steel is 7800 kg/m3 while Poisson’s ratio is 0.5. Calculate the outer radius of the
flywheel disk and the maximum stresses induced in it.

ii) The turning moment diagram of a multi-cylinder engine is drawn with a scale of (1 mm
= 1°) on the abscissa and (1 mm = 199 N-m) on the ordinate. The intercepted areas between
the torque developed by the engine and the mean resisting torque of the machine, taken in
order from one end are – 350, + 800, – 600, + 900, – 550, + 450 and –650 mm 2. The engine is
running at a mean speed of 700 rpm and the coefficient of speed fluctuations is limited to
0.02. A rimmed flywheel made of grey cast iron FG 200 (ρ= 7100 kg/m 3) is provided. The
spokes, hub and shaft are assumed to contribute 10% of the required moment of inertia.
The rim has rectangular cross-section and the ratio of width to thickness is 1.5. Determine
the dimensions of the rim.