EMD IMP QUESTIONS

Q1. Attempt any FIVE of the following: (10 Marks)

a) Define the factor of safety for ductile and brittle material.
b) List four properties desirable for spring material.
c) List four applications of knuckle joints.
d) Name four types of keys.
e) List any four applications of power screws.
f) Classify springs.
g) Give four applications of gear drive.
h) Define Machine Design.
i) State materials used for helical springs.
j) Define:
(i) Spring index
(ii) Spring stiffness
(iii) Classify bearing
(iv) Solid length
k) State two examples where hollow shafts are used.

n) Draw the symbolic representation of the following types of weld:

(i) Weld all around
(ii) Single U-butt weld
o) State the significance of 'Wahl's factor'.
p) State any four applications of the rolling contact bearing.
q) Explain the term 'Endurance Limit'.
r) List any four applications of Foot lever.
Q2. Attempt any THREE of the following: (12 Marks)

a) Explain the failure of cotter in bending with a suitable sketch and strength equation.
b) Write Lewis equation for the strength of gear tooth and give the meaning of each term.
c) Draw freehand sketches of thread profiles (any four) with full details.
d) Explain steps involved in the general design procedure.
e) Prove that a square key crushing stress is twice the shearing stress.
f) State the strength equations of double parallel fillet weld and single transverse fillet weld with
neat sketches.
g) Explain self-locking and overhauling property of screw.

Q3. Attempt any THREE of the following: (12 Marks)

a) Explain the construction of a leaf spring with a neat sketch.
b) Explain with neat sketches different types of radial ball bearings.
c) Design a helical compression spring for a maximum load of 1000 N for a deflection of 25 mm
using the value of spring index as 5. The maximum permissible shear stress for spring wire is
420 MPa and modulus of rigidity is 84 kN/mm².

d) Explain selection of ball bearing using the manufacturer’s catalogue.

e) Sketch S-N curve & explain the term endurance limit.

Q4. Attempt any TWO of the following: (12 Marks)

a) A screw jack is to lift a load of 80 kN through a height of 400 mm. The elastic strength of
screw material in tension and compression is 200 MPa and in shear 120 MPa. The material for
nut is phosphorus bronze for which the elastic limit may be taken as 100 MPa in tension, 90 MPa
in compression, and 80 MPa in shear. The bearing pressure between the nut and the screw is not
to exceed 18 N/mm². Design and draw the screw jack. Take FOS = 2.
b) Design a cast iron protective type flange coupling to transmit 15 kW at 900 rpm from an
electric motor to a compressor. Use the following permissible stresses:
Shear stress for shaft, bolt and key = 40 MPa
Crushing stress for Bolt and key = 80 MPa
Shear stress for cast iron = 8 MPa.
c) Draw a neat sketch of a turnbuckle. Explain its design procedure.
d) A shaft is required to transmit 1 MW power at 240 rpm. The shaft must not twist more than 1°
on a length of one meter. If the modulus of rigidity for the material of the shaft is 80 kN/mm²,
find the diameter of shaft and the stress induced in it.
e) The pull in the rod of a roof truss is 44 kN. Design a suitable adjustable screw joint. The
permissible tensile and shear stresses are 75 MPa and 37.5 MPa respectively.
f) State the necessity of 'Ergonomic' considerations while designing products. Explain any four
ergonomic considerations in the designing of machine elements.
g) Explain with the help of neat sketches three basic types of lever. State one application of each
type.
h) Determine the diameter of a hollow shaft having inside diameter 0.6 of outside diameter. The
shaft is driven by 900 rpm overhang pulley. The weight of the pulley is 600 N. The overhang is
250 mm and tension in tight and slack sides are 2900 N and 1000 N respectively. Assume t = 80
N/mm² and r = 60 N/mm².

Q5. Attempt any TWO of the following: (12 Marks)

a) Define the factor of safety and state the factors affecting on the selection of the factor of safety
for ductile and brittle material.
b) A mild steel bracket as shown in Fig. No. 1 is subjected to a pull of 6000 N acting at 45° to its
horizontal axis. The bracket has a rectangular section whose depth is twice the thickness. Find
the cross sectional dimensions of the bracket, if the permissible stress in the material of the
bracket is limited to 60 MPa.
c) Sketch protective type flange coupling & explain its design procedure.
d) A vertical 2-start square threaded screw of 120 mm mean diameter and 24 mm pitch supports
a vertical load of 20 kN. The axial thrust in the screw is taken by a collar bearing of 300 mm
outside dia. and 150 mm inside dia. Find the force required at the end of the lever, which is 400
mm long in order to lift and lower the load - coefficient of friction for screw & nut is 0.18 and
for collar bearing is 0.25.

Q6. Attempt any TWO of the following: (12 Marks)

a) A closely coiled helical spring is made of 10 mm diameter steel wire. The coil consists of 10
complete turns with a mean diameter of 120 mm. The spring carries an axial load of 200 N.
Determine the shear stress in the spring neglecting the effect of stress concentration. Determine
also the deflection of the spring, its stiffness and strain energy stored by it if the modulus of
rigidity of the spring material is 80 kN/mm².
b) A plate 100 mm wide and 10 mm thick is to be welded to another plate by means of double
parallel fillets. The plates are subjected to a static load of 90 kN. Find the length of weld if the
permissible shear stress of weld does not exceed 60 MPa.
c) A right angled bell crank lever has horizontal arm 500 mm long and load of 5 kN acts
vertically down ward through a pin forked end of this arm. At the end of 150 mm long arm which
is perpendicular to 500 mm long arm, a effort P acts at right angles to the axis of 150 mm arm
through a pin into a forked end. The lever consists of forged steel material and a pin at fulcrum.
Design:
i) Fulcrum pin and
ii) The lever.
Take following data for pin and lever material:
Safe stress in tension = 80 N/mm²
Safe stress in shear = 60 N/mm²
Safe bearing pressure on pins = 10 N/mm²
Take rectangular cross section of the lever near fulcrum with b = 3t, where t is thickness and b is
depth of lever.
d) Explain with neat sketches bolt of uniform strength.
e) A cylinder head of steam engine is held in position by M20 bolts. The effective diameter of
cylinder is 350 mm and steam pressure is 0.75 N/mm². If the bolts are not initially stressed, find
the number of bolts required. Take working stress for the bolt material as 250 N/mm².
f) Design a closed coil helical spring for a service load ranging from 2207 N to 2698 N. The
axial deflection of spring is 6 mm. Assume spring index as 5. The permissible shear stress is 420
N/mm². Modulus of rigidity is 84 × 103 N/mm².
g) Compare the weight, strength and stiffness of a hollow shaft of the same external diameter as
that of solid shaft. The inside diameter of the hollow shaft is half the external diameter. Both the
shafts have the same material and length.
h) A plate 75 mm wide and 12.5 mm thick is to be joined with another plate by single transverse
and parallel fillet weld. Maximum tensile and shear stresses are 70 N/mm² and 56 N/mm²
respectively. Find the length of each parallel fillet weld if joint is subjected to 90 kN.
i) Design “C” clamp frame for a total clamping force of 20 kN. The cross-section of the frame is
rectangular and width to thickness ratio is 2. The distance between the load line and natural axis
of rectangular cross section is 120 mm and the gap between two faces is 180 mm. The frame is
made of cast steel for which maximum permissible tensile stress is 100 N/mm².
j) A helical valve spring is to be designed for an operating load range of approximately 135 N.
The deflection of the spring for the load range is 7.5 mm. Assume the spring index is 5. The
permissible shear stress for the material of the spring = 480 MPa and its modulus of rigidity = 80
kN/mm².
Design the spring.
Take Wahl’s correction factor = 4C4C1C2 + C0.615
Where C = Spring index.
k) Explain following:
i) Effect of keyway on the strength of shaft.
ii) "Square key is equally strong in shearing and crushing" - prove.