VIGNAN’S INSTITUTE OF INFORMATION TECHNOLOGY: VISAKHAPATNAM

Department of Mechanical Engineering

Design of Machine Members (1003232203)

Unit-1

Short Answer Questions

1. Give the list of various mechanical properties of materials.
2. Enumerate the most commonly used engineering materials.
3. Calculate the force required to punch a circular blank of 60 mm diameter in a plate of
5 mm thick. The ultimate shear stress of the plate is 350 N/mm2.
4. Define factor of safety. Why it is important in machine design.
5. Enumerate various general considerations in machine design?
6. List the theories of failure used under static load.
7. When do you use maximum shear stress theory of failure?
8. A shaft is transmitting 90 kW at 160 r.p.m. If the allowable shear stress in the material
is 70 MPa, find the diameter for the shaft.
9. A simply supported beam of span length 6m and 75 mm diameter carries a udl of 1.5
kN/m. Determine the maximum value of bending stress?
10. Illustrate stress concentration in a plate with hole.
11. Define the following.
(i)Theoretical stress concentration factor
(ii) Endurance limit
(iii)The notch sensitivity factor
12. Draw the S-N curve and show all the stress limits.
13. Discuss the methods to reduce stress concentration.
14. Sketch the failure criteria according to Soderberg’s theory. Mention its equation.
15. Describe the failure criteria according to Goodman’s theory. Mention its equation.
16. Distinguish between fluctuating stress, repeated stress, and reversed stress.
17. Describe the method to reduce stress concentration in any two machine components.
18. Distinguish between LCF and HCF.
19. Define the efficiency of welded joint?
20. Enumerate the applications of bolted and welded joints.

Descriptive Questions

1. Classify various engineering materials with suitable examples.

2. List out various mechanical engineering properties and explain any five of them.
3. What is machine design. Describe the procedure used in machine design
4. Explain the general considerations used in machine design.
5. Describe the theories of failures used for static loads.
6. Discuss the methods used to reduce stress concentration with suitable examples.
7. A shaft is transmitting 98 kW at 180 r.p.m. If the allowable shear stress in the material is
60 MPa, find the suitable diameter for the shaft. The shaft is not to twist more than 1° in a
length of 3 metres. Take C = 80 GPa.
8. A pull of 80 kN is transmitted from a bar X to the bar Y through a pin as shown in Figure
below. If the maximum permissible tensile stress in the bars is 100 N/mm 2 and the
permissible shear stress in the pin is 80 N/mm2, find the diameter of bars and of the pin.

9. A hollow shaft is required to transmit 600 kW at 110 r.p.m., the maximum torque being
20% greater than the mean torque. The shear stress is not to exceed 63 MPa and twist in a
length of 3 metres not to exceed 1.4 degrees. Find the external diameter of the shaft, if the
internal diameter to the external diameter is 3/8. Take modulus of rigidity as 84 GPa.
10. A solid shaft, as shown in Figure below, is subjected to a bending load of 3 kN, pure
torque of 1000 N-m and an axial pulling force of 15 kN. Calculate the stresses at A and
B.
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. Take
permissible tensile stress at yield point = 100 MPa and Poisson’s ratio = 0.3.
12. A cylindrical shaft made of steel of yield strength 700 MPa is subjected to static loads
consisting of bending moment 10 kN-m and a torsional moment 30 kN-m. Determine
the diameter of the shaft using any two theories of failure, and assuming a factor of
safety of 2. Take E = 210 GPa and Poisson's ratio = 0.25.
13. A mild steel shaft of 50 mm diameter is subjected to a bending moment of 2000 N-m
and a torque T. If the yield point of the steel in tension is 200 MPa, find the maximum
value of this torque without causing yielding of the shaft according to 1. the maximum
principal stress; 2. the maximum shear stress; and 3. the maximum distortion strain
energy theory of yielding.
14. Estimate the maximum stress induced in the following two cases by taking stress
concentration into account:
i) A rectangular plate 60 mm × 10 mm with a hole 12 mm diameter as shown in Fig.
(a) and subjected to a tensile load of 12 kN. Take Kt = 2.5
ii) A stepped shaft as shown in Fig. (b) and carrying a tensile load of 12 kN. Take Kt =
1.6.

15. A machine component is subjected to a flexural stress which fluctuates between + 300
MN/m2 and – 150 MN/m2. Determine the value of minimum ultimate strength
according to 1. Goodman relation; and 2. Soderberg relation. Take yield strength =
0.55 times ultimate strength; Endurance strength = 0.5 times ultimate strength; and
factor of safety = 2.
16. A bar of circular cross-section is subjected to alternating tensile forces varying from a
minimum of 200 kN to a maximum of 500 kN. It is to be manufactured of a material with
 an ultimate tensile strength of 900 MPa and an endurance limit of 700 MPa. Determine the
diameter of bar using safety factors of 3.5 related to ultimate tensile strength and 4.0 related
to endurance limit and a stress concentration factor of 1.65 for fatigue load. Use Goodman
straight line as basis for design.
17. Determine the diameter of a circular rod made of ductile material with a fatigue strength
(complete stress reversal), σe = 265 MPa and a tensile yield strength of 350 MPa. The
member is subjected to a varying axial load from Wmin = – 300 kN to Wmax = 700 kN and
has a stress concentration factor = 1.8. Use factor of safety as 2.
18. A circular bar of 500 mm length is supported freely at its two ends. It is acted upon by a
central concentrated cyclic load having a minimum value of 20 kN and a maximum value
of 50 kN. Determine the diameter of bar by taking a factor of safety of 1.5, size effect of
0.85, surface finish factor of 0.9. The material properties of bar are follows: ultimate
strength = 650 MPa, yield strength= 500 MPa and endurance strength = 350 MPa.
19. A 50 mm diameter shaft is made from carbon steel having ultimate tensile strength of
630 MPa. It is subjected to a torque which fluctuates between 2000 N-m to – 800 N-m.
Using Soderberg method, calculate the factor of safety. Assume suitable values for any
other data needed. Assume the yield stress (𝜎𝑦 ) for carbon steel in reversed bending as
510 N/mm2, surface finish factor (𝐾𝑠𝑢𝑟 ) as 0.87, size factor (𝐾𝑠𝑧 ) as 0.85 and fatigue
stress concentration factor (𝐾𝑓𝑠 ) as 1.
20. A cantilever beam made of cold drawn carbon steel of circular cross-section as shown in
Fig. is subjected to a load which varies from – F to 3F. Determine the maximum load that
this member can withstand for an indefinite life using a factor of safety as 2. The theoretical
stress concentration factor is 1.42 and the notch sensitivity is 0.9. Assume the following
values: Ultimate stress = 550 MPa; Yield stress = 470 MPa; Endurance limit = 275 MPa;
Size factor = 0.85; Surface finish factor = 0.89. (Use Soderberg's formula)

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