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. Define endurance limit. What are all the factors affecting endurance strength [CO1,K1]
2. Sketch goodman and soderberg diagram and locate safe design region [CO1,K2]
3. Classify the types of keys. [CO2,K2]
4. Two blocks diametrically opposite to each other are used in a block brake. Why? [CO2,K2]
5. List some types of commonly used thread forms. [CO3,K2]
6. When will the weld deposit be weaker? [CO3,K2]
7. What is solid length in a spring? [CO4,K2]
8. Why heat dissipation is necessary in clutches? [CO4,K2]
9. How can be the equivalent loads in a bearing is calculated? [CO5,K2]
10. Define coefficient of fluctuation of speeds in case of flywheels. [CO5,K2]

PART – B (5 X 16 = 80 Marks)
11. a. i) A hot rolled steel shaft is subjected to a torsional load that varies from 300 [CO1,K3]
kNmm clockwise to 100 kN-mm anti-clockwise and an applied bending moment
at a critical section varies from + 400 kN-mm to – 200 kN-mm. The shaft is of
uniform cross-section and no keyway is present at the critical section. Determine
the required shaft diameter by taking factor of safety 1.5. For the material, take
ultimate tensile stress as 560 MPa, stress at yield point 420 MPa, design stress is
280 MPa. Also take the modification factor as 0.62, size correction factor as 0.85, the
load factor for bending as 1 and the load factor for torsion as 0.58.

ii) A wall bracket with a rectangular cross-section is shown in Fig. The depth of the cross-
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.

(Or)
11. b. i) A cantilever beam made of cold drawn steel 40C8 (Sut = 600 N/mm 2 and [CO1,K3]
 Syt = 380 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. The notch sensitivity factor at the fillet is 0.9. Determine the
diameter d of the beam at the fillet cross-section using Gerber curve as
failure criterion.

ii). A steel member is subjected to a 3 dimensional stress system and the

resulting principal stress are 120 N/mm2 tension, 80 N/mm2 and 40 N/mm2
compression. If the proportional limit of the material in simple tension is
280 N/mm2 and its poissons ratio is 0.3. determine factor of safety according
to a) Maximum principal stress theory
b) Maximum principal strain theory and
c) Maximum shear stress theory

12. a. i) Determine the required standard diameter of a uniform circular shaft [CO2,K3]
carrying 2 pulleys of weight 2 kN each. The shaft 750 mm long is supported
at the end and carries 2 pulleys at 250 mm and 500 mm from the left end.
Pull on the right pulley is 10 kN vertically downwards. The shaft transmits
a torque of 3 kN-m between the pulleys. Assume k b=kt=1.5 and allowable
shear stress of 70 N/mm2

ii) It is required to design a square key for fixing a gear on a shaft of 25 mm

diameter. The shaft is transmitting 15 kW power at 720 rpm to the gear. The
key is made of steel 50C4 (Syt = 460 N/mm2) and the factor of safety is 3.
For key material, the yield strength in compression can be assumed to be
equal to the yield strength in tension.Determine the dimensions of the key.
(Or)
12. b. i) A 400 mm radius brake drum contacts a single shoe as shown in fig. and [CO2,K3]
sustains 200 N-m torque at 500 rpm. For a coefficient of friction 0.25,
determine:
1. Normal force on the shoe.
2. Required force F to apply the brake for clockwise rotation.
3. Required force F to apply the brake for counter clockwise rotation.
 4. The dimension c required to make the brake self-locking, assuming the
other dimensions remains the same.
5. Heat generated.

ii) The layout of a double block brake is shown in fig. The brake is rated at
250N.m at 650 r.p.m. The drum diameter is 250mm assume coefficient of
friction to be 0.3 and for conditions of service a pv value of 1000(kpa) m/s
may be assumed.
Determine
(a)Spring force S required to set the brake and
(b)Width of shoes
(c)Which shoe will have greater rate of wear and what will be the ratio of
rates of wear of the two shoes?

13. a. i) A bracket as shown in Fig. is fitted to a wall with 5 bolts, three at the top and two at the [CO3,K3]
bottom, with all bolts equally spaced. A load of 20000 N is acting at an eccentricity of 200
mm. Vertical distance of first and second rows from the hinge point are 50 mm and 250
mm respectively. Select a suitable size of the bolt.

ii) Find suitable bolt for the application shown in Fig.

 (Or)
13. b. i) A welded connection, as shown in Fig, is subjected to an eccentric force [CO3,K3]
of 60 kN in the plane of the welds. Determine the size of the welds, if the
permissible shear stress for the weld is 100 N/mm2. Assume static
conditions.

ii) A bracket is welded to the vertical plate by means of two fillet welds as
shown in Fig. Determine the size of the welds, if the permissible shear stress
is limited to 70 N/mm2.

14. a. i) A helical compression spring is used to absorb the shock. The initial [CO4,K3]
compression of the spring is 30mm, and it is further compressed by 50mm
while absorbing the shock. The spring is to absorb 250kJ of energy during
the process. The spring index can be taken as 6. The spring is made of
patented and cold drawn steel wire with an ultimate tensile strength of 1500
N/mm2 and modulus of rigidity of 81370 N/mm 2. The permissible shear
stress for the spring wire should be taken as 30% of the ultimate tensile
strength. Design the spring and calculate. (i) Wire diameter (ii) Mean coil
Diameter (iii) Number of active turns (iv) Free length (v) Pitch of turns

ii) A semi elliptic leaf spring used for automobile suspension consists of
three extra full-length leaves and 15 graduated leaves including the master
leaf. The centre to centre distance between two eyes of the spring is 1.5m.
The maximum force acting on spring is 100 kN. For each leaf the ratio of
width to thickness is 9:1. E=200 GPa, 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 450MPa. Determine (i) the width and thickness of leaves,
(ii) the initial nip; and (iii) the initial preload required to close the gap C
between extra full-length leaves and graduated length leaves.
(Or)
14 b. i) Design a single plate clutch consist of two pairs of contacting surfaces for [CO4,K3]
a torque capacity of 200 N-m. Due to space limitation the outside diameter
of the clutch is to be 250mm

ii) A Multiple plate clutch has steel on bronze is to transmit 8 KW at 1440

rpm. The inner diameter of the contact is 80mm and outer diameter of
contact is140 mm. The clutch operates in oil with coefficient of friction of
0.1. The overage allowable pressure is 0.35Mpa. Assume uniform wear
theory and determine the following.
a) Number of steel and bronze plates
b) Axial force required
c) Actual maximum pressure

15 a. i) A Ball Bearing works on following work cycle [CO5,K3]

Sl. NoRadial Speed Element

load (rpm) time %
(kN)
1 3000 720 30
2 7000 1440 50
3 5000 900 20
The Dynamic Load carrying capacity of the bearing is 16.6 KN. Consider
work cycle on One Minute revolution.

Calculate :

 Average speed rotation

 Equivalent radial load
 The Bearing Life in Hours.
ii) Following data are given for a 360º hydrodynamic bearing:
Radial load=3.2 kN
Journal speed= 1490 r.p.m.
Journal diameter=50 mm
Bearing length=50mm
Radial clearance=0.05 mm
Viscosity of the lubricant= 25 cP
Assuming that the total heat generated in the bearing is carried by the total
oil flow in the bearing, calculate:
• Power lost in friction;
• The coefficient of friction;
• Minimum oil film thickness
• Flow requirement in 1/min; and
• Temperature rise.

(Or)
 b. i) A multi-cylinder engine is to run at a constant load at a speed of 600 [CO5,K3]
r.p.m. On drawing the crank effort diagram to a scale of 1 m = 250 N-m and
1 mm = 3º, the areas in sq mm above and below the mean torque line are as
follows: + 160, – 172, + 168, – 191, + 197, – 162 sq mm. The speed is to be
kept within ± 1% of the mean speed of the engine. Calculate the necessary
moment of inertia of the flywheel. Determine suitable dimensions for cast
iron flywheel with a rim whose breadth is twice its radial thickness. The
density of cast iron is 7250 kg/m 3, and its working stress in tension is 6
MPa. Assume that the rim contributes 92% of the flywheel effect.

ii) The turning moment diagram for a petrol engine is drawn to the
following scales: Turning moment, 1 mm = 5 N-m; Crank angle, 1 mm = 1º.
The turning moment diagram repeats itself at every half revolution of the
engine and the areas above and below the mean turning moment line, taken
in order are 295, 685, 40, 340, 960, 270 mm 2. Determine the mass of 300 mm
diameter flywheel rim when the coefficient of fluctuation of speed is 0.3%
and the engine runs at 1800 r.p.m. Also determine the cross-section of the
rim when the width of the rim is twice of thickness. Assume density of rim
material as 7250 kg /m3.

Bloom’s Remembering Understanding Applying Analyzing Evaluating Creating

Taxonomy (K1) (K2) (K3) (K4) (K5) (K6)
Level
Percentage