Department of Mechanical Engineering

IIIYear / V Semester

Question Bank

Course Code: ME3591

Course Name: DESIGN OF MACHINE ELEMENTS

Unit – I: STEADY STRESSES AND VARIABLE STRESSES IN MACHINE MEMBERS

PART A
QNo Bloom’s
Questions COs
Level
1. Ductile material will fail due to ………………….load CO1 K1
because…………………………………………………….
2. Define endurance limit. CO1 K1
3. What are the various phases of design process? CO1 K1
4. What are the factors affecting endurance strength? CO1 K2
5. What are the types of variable stresses? CO1 K1
6. Differentiate between repeated stress and reversed stress. CO1 K1
7. Distinguish between brittle fracture and ductile fracture. CO1 K1

8. What are the factors to be considered in the selection of CO1 K1

materials for a machine element?
9. What are various theories of failure? CO1 K1
10. Give some methods of reducing stress concentration. CO1 K1
11. What is the use of Goodman and Soderberg diagrams? CO1 K1
12. What is an S-N Curve? CO1 K1
13. What is curved beam? CO1 K1
14. What is principle stress and principle plane? CO1 K1
15. Why von mises theory is known as optimum theory? CO1 K1
Part – B
The load on a bolt consists of an axial pull of 10kN together
with a transverse shear force of 5Kn. Find the diameter of bolt
required according to CO1
1 K3
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.
2 Find the stresses in the inner and outer fibers at the given CO1 K3
section
 The frame of a punch press is shown in Fig.. Find the
stresses at the inner and outer surface at section X-X of the
frame, if W = 5000 N.

3 CO1 K3

A bar of circular cross section is subjected to alternating

tensile forces varying from a minimum of 200KN to a
maximum of 500KN. It is to be manufactured of material
with an ultimate tensile strength of 900Mpa and an
4 endurance limit of 700Mpa. Determine the diameter of bar CO1 K3
using safety factors of 3.5 related to ultimate tensile
strength and 4 related to endurance limit and stress
concentration factor of 1.65 for a fatigue load. Use Goodman
straight line as basis for design.
5 An overhang crank with pin and shaft is shown in Fig. 5.18. A CO1 K3
tangential load of 15 kN acts on the crank pin. Determine the
maximum principal stress and the maximum shear stress at
the centre of the crankshaft bearing.
 A mild steel bracket as shown in fig. (1) is subjected to a
pull of 6000N acting at45 0 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.

6 CO1 K3

Find the maximum stress induced in the following cases

taking stress concentration into account:1. A rectangular
plate 60 mm × 10 mm with a hole 12 diameter as shown in
Fig. (a) and subjected to a tensile load of 12 kN.
2. A stepped shaft as shown in Fig. (b) and carrying a tensile
load of 12 kN.
7 CO1 K3

A steel connecting rod is subjected to a completely reversed

axial load of 160 kN.Suggest the suitable diameter of the rod
8 using a factor of safety 2. The ultimate tensile strength of the CO1 K3
material is 1100 MPa, and yield strength 930 MPa. Neglect
column action and the effect of stress concentration.
PART –C
1 Determine the thickness of a 120 mm wide uniform plate for safe CO1 K3
continuous operation if the plate is to be subjected to a tensile
 load that has a maximum value of 250 kN and a minimum value
of 100 kN. The properties of the plate material are as follows:
Endurance limit stress = 225 MPa, and Yield point stress = 300
MPa. The factor of safety based on yield point may be taken as
1.5.
Find the stresses in the inner and outer fibers at the given
section

2 CO1 K3

Unit II SHAFTS AND COUPLINGS

Q. CO’ Bloom’s
Questions Level
No s
1 Define the term critical speed CO2 K1
2 Differentiate axle and shaft CO2 K1
3 List the various failures occurred in sunk keys. CO2 K1
4 When is square key used? CO2 K1
5 Under what circumstances flexible couplings are used? CO2 K1
6 What are the purposes in machinery for which couplings are used? CO2 K1
7 What are the types of keys? CO2 K1
8 What are the factors to be considered to design a shaft? CO2 K1
9 How is the power transmitted from one shaft to another shaft? CO2 K1
10 Why is hollow shaft preferred? CO2 K1
11 What are the materials used to design the components of flange CO2 K1
couplings?
12 What is the purpose of splined shaft? CO2 K1
13 Draw the diagram of muff coupling and mark the parts CO2 K1
14 Draw the diagram of flange coupling and mark the parts CO2 K1
15 Draw the diagram of woodruff key CO2 K1
Part – B
1 A hollow steel shaft transmits 600 kW at 500 r.p.m. The maximum shear CO2 K3
stress is 62.4MPa. Find the outside and inside diameter of the shaft, if
the outer diameter is twice of inside diameter, assuming that the
 maximum torque is 20% greater than the mean torque.
Two 400 mm diameter pulleys are keyed to a simply supported shaft
500 mm apart. Each pulley is 100 mm from its support and has
horizontal belts, tension ratio being 2.5. If the shear stress is to be
2 limited to 80 MPa while transmitting 45 kW at 900 r.p.m., find the shaft CO2 K3
diameter if it is to be used for the input-output belts being on the same
or opposite sides.

Fig. shows a shaft from a hand-operated machine. The frictional

torque in the journal bearings at A and B is 15 N-m each. Find the
diameter ( d ) of the shaft (on which the pulley is mounted) using
maximum distortion energy criterion. The shaft material is 40 C 8 steel
for which the yield stress in tension is 380 MPa and the factor of safety
is 1.5

3 CO2 K3

4 CO2 K3

A shaft made of steel receives 7.5 kW power at 1500 r.p.m. A pulley

mounted on the shaft as shown in Fig. has ratio of belt tensions 4.The
gear forces are as follows: Ft = 1590 N; Fr = 580 N Design the shaft
diameter by maximum shear stress theory. The shaft material has the
following properties: Ultimate tensile strength = 720 MPa; Yield strength
= 380 MPa; Factor of safety = 1.5.
The internal diameter of a hollow shaft is 2/3 rd of its external diameter.
5 Compare the strength and stiffness of the shaft with that of a solid shaft CO2 K3
of the same material.
The shaft of an axial flow rotary compressor is subjected to a
maximum torque of 2000 N-m and a maximum bending moment of
4000 N-m. The combined shock and fatigue factor in torsion is 1.5 and
6 that in bending is 2. Design the diameter of the shaft, if the shear CO2 K3
stress in the shaft is 50 MPa. Design a hollow shaft for the above
compressor taking the ratio of outer diameter to the inner diameter as
2. What is the percentage saving in material? Also compare the
stiffness.
7 A steel shaft has a diameter of 25 mm. The shaft rotates at a speed of CO2 K3
600 r.p.m. and transmits 30 kW through a gear. The tensile and yield
strength of the material of shaft are 650 MPa and 353 MPa respectively.
 Taking a factor of safety 3, select a suitable key for the gear. Assume
that the key and shaft are made of the same material.
Design a cast iron protective flange coupling to connect two shafts in
order to transmit 7.5 kW at 720 r.p.m. The following permissible stresses
8. may be used : Permissible shear stress for shaft, bolt and key material = CO2 K3
33 MPa Permissible crushing stress for bolt and key material = 60 MPa
Permissible shear stress for the cast iron = 15 MPa
PART –C
Two shafts made of plain carbon steel are connected by a rigid
protective type flange coupling. The shafts are running at 500 r.p.m.
and transmit 25 kW power. Design the coupling completely for overload
capacity 25 per cent in excess of mean transmitted torque capacity.
Assume the following permissible stresses for the coupling components :
Shaft — Permissible tensile stress = 60 MPa; Permissible shear stress =
1. CO2 K3
35 MPa
Keys — Rectangular formed end sunk key having permissible
compressive strength =60 MPa Bolts — Six numbers made of steel
having permissible shear stress = 28 MPa
Flanges — Cast iron having permissible shear stress = 12 MPa
Draw two views of the coupling you have designed
A flanged protective type coupling is required to transmit 50 kW at
2000 r.p.m.. Find:
(a) Shaft diameters if the driving shaft is hollow with di / d0 = 0.6
and driven shaft is a solid shaft. Take τ = 100 MPa.(b) Diameter of
bolts, if the coupling uses four bolts. Take σc = σt = 70 MPa and τ= 25
2. MPa. Assume pitch circle diameter as about 3 times the outside CO2 K3
diameter of the hollow shaft.(c) Thickness of the flange and diameter of
the hub. Assume σc = 100 MPa and τ= 125 MPa.(d) Make a neat free
hand sketch of the assembled coupling showing a longitudinal
sectional elevation with the main dimensions. The other dimensions
may be assumed suitably.

Unit III TEMPORARY AND PERMANENT JOINTS

Q. CO’ Bloom’s
Questions Level
No s
1 How is a bolt designated? CO3 1
2 What factors influence the amount of initial tension? CO3 1
3 What stresses act on screw fastenings? CO3 1
4 What are the advantages of screwed fasteners? CO3 1
6 What are the failures in riveted joint? CO3 1
7 What do you mean by back pitch? CO3 1
8 Differentiate Knuckle and coupling CO3 1
9 What are the types of welded joints? CO3 1
10 What are the two types of stresses are induced in eccentric loading of CO3 1
loaded joint?
11 What are the two cases of welded joints subjected to eccentric loading? CO3 1
12 What are the two types of fillet weld? CO3 1
13 What are the practical applications of welded joints? CO3 1
14 Draw the diagram of rivet mark the parts CO3 1
15 Write unwin’s formula CO3 1
 PART- B
A bracket is bolted to a column by 6 bolts of equal size as shown in
Fig. 11.51. It carries a load of 50 kN at a distance of 150 mm from the
centre of column. If the maximum stress in the bolts is to be limited to
150 MPa, determine the diameter of bolt.

1 CO3 3

Design a knuckle joint to connect two mild steel bars under a tensile
2 load of 25 kN. The allowable stresses are 65 MPa in tension, 50 CO3 3
MPa in shear and 83 MPa in crushing.
A bracket is riveted to a columm by 6 rivets of equal size as shown in
Fig. 9.38. It carries a load of 100 kN at a distance of 250 mm from the
column. If the maximum shear stress in the rivet is limited to 63 MPa,
find the diameter of the rivet.

3 CO3 3

A triple riveted butt joint with equal double cover plates (zig-zag
riveting) is used for the longitudinal joint of a Lancashire boiler of 2.5 m
internal diameter. The working steam pressure is 1.12 N/mm2 and the
4 efficiency of the joint is 85 per cent. Calculate the plate thickness for CO3 3
mild steel of 460 MPa ultimate tensile strength. Assume ratio of tensile
to shear stresses as 7/6 and factor of safety 4. The resistance of the
rivets in double shear is to be taken as 1.875 times that of single shear.
Design a suitable circumferential joint also
5 A bracket is welded to the side of a column and carries a vertical load CO3 3
P, as shown in
Fig. . Evaluate P so that the maximum shear stress in the 10 mm fillet
welds is 80 MPa.
 A bracket, as shown in Fig. 10.39, carries a load of 40 kN. Calculate the
size of weld, if the allowable shear stress is not to exceed 80 MPa

6 CO3 3

Design and draw a cotter joint to support a load varying from 30 kN in

compression to 30 kN in tension. The material used is carbon steel for
7 which the following allowable stresses may be used. The load is applied CO3 3
statically. Tensile stress = compressive stress = 50 MPa ; shear stress =
35 MPa and crushing stress = 90 MPa
A rectangular cross-section bar is welded to a support by means of fillet
welds as shown in Fig. . Determine the size of the welds, if the permiss-
ible shear stress in the weld is limited to 75 MPa

8 CO3 3

PART C
1 A bracket carrying a load of 15 kN is to be welded as shown in Fig. Find CO3 3
the size of weld required if the allowable shear stress is not to exceed 80
 MPa.
A bracket is bolted to a column by 6 bolts of equal size as shown in Fig..
It carries a load of 50 kN at a distance of 150 mm from the centre of
column. If the maximum stress in the bolts is to be limited to 150 MPa,
determine the diameter of bolt.

2 CO3 3

Unit IV ENERGY STORING ELEMENTS AND ENGINE COMPONENTS

Q. CO’ Bloom’s
Questions Level
No s
1 What are the various types of springs? CO4 1
2. State any two functions of springs CO4 1
3 Classify the helical springs CO4 1
4 Define : Leaf springs CO4 1
5 Draw the diagram of bellevile spring CO4 1
6 What is spring index (C)? CO4 1
7 What is solid length? CO4 1
8 What are the end conditions of spring? CO4 1
9 What is buckling of springs? CO4 1
10 What is surge in springs? CO4 1
11 What is a laminated leaf spring? CO4 1
12 Define spring rate (stiffness). CO4 1
13 What is nipping of laminated leaf spring? CO4 1
14 What are the various application of springs? CO4 1
15 Define free length. CO4 1
PART - B
1 A railway wagon weighing 50 kN and moving with a speed of 8 km per CO4 3
hour has to be stopped by four buffer springs in which the maximum
compression allowed is 220 mm. Find the number of turns in each spring
 of mean diameter 150 mm. The diameter of spring wire is 25 mm. Take
G = 84 kN/mm2
A semi-elliptical spring has ten leaves in all, with the two full length
leaves extending 625 mm. It is 62.5 mm wide and 6.25 mm thick.
Design a helical spring with mean diameter of coil 100 mm which will
2 have approximately the same induced stress and deflection for any CO4 3
load. The Young’s modulus for the material of the semi-elliptical spring
may be taken as 200 kN/mm2 and modulus of rigidity for the
material of helical spring is 80 kN/mm2.
Design a leaf spring for the following specifications : Total load = 140
kN ; Number of springs supporting the load = 4 ; Maximum number of
3 leaves = 10; Span of the spring = 1000 mm ; Permissible deflection = CO4 3
80 mm. Take Young’s modulus, E = 200 kN/mm2 and allowable stress in
spring material as 600 MPa.
Design a compression helical spring to carry a load of 500 N with a de-
flection of 25 mm. The spring index may be taken as 8. Assume the fol-
4 lowing values for the spring material:Permissible shear stress = 350 CO4 3
MPaModulus of rigidity = 84 kN/mm2

Design a helical spring for a spring loaded safety valve for the following
conditions : Operating pressure = 1 N/mm2 Maximum pressure when the
valve blows off freely = 1.075 N/mm2 Maximum lift of the valve when the
5 2 CO4 3
pressure is 1.075 N/mm = 6 mm Diameter of valve seat = 100 mm
Maximum shear stress = 400 MPa Modulus of rigidity = 86 kN/mm2
Spring index = 5.5
A vertical spring loaded valve is required for a compressed air receiver.
The valve is to start opening at a pressure of 1 N/mm2 gauge and must
be fully open with a lift of 4 mm at a pressure of 1.2 N/mm2 gauge. The
6 diameter of the port is 25 mm. assume the allowable shear stress in CO4 3
steel as 480 MPa and shear modulus as 80 kN/mm2. Design a suitable
close coiled round section helical spring having squared ground
ends. Also specify initial compression and free length of the spring.
Design and draw a valve spring of a petrol engine for the following oper-
ating conditions : Spring load when the valve is open = 400 N Spring load
7 when the valve is closed = 250 N Maximum inside diameter of spring = CO4 3
25 mm Length of the spring when the valve is open = 40 mm Length of
the spring when the valve is closed = 50 mm Maximum permissible
shear stress = 400 MPa
Design a close coiled helical compression spring for a service load
ranging from 2250 N to 2750 N. The axial deflection of the spring for the
8 load range is 6 mm. Assume a spring index of 5. The permissible shear CO4 3
stress intensity is 420 MPa and modulus of rigidity, G = 84 kN/mm 2.
Neglect the effect of stress concentration. Draw a fully dimensioned
sketch of the spring, showing details of the finish of the end coils.
PART – C
Design a helical spring for a spring loaded safety valve (Ramsbottom
safety valve) for the following conditions : Diameter of valve seat = 65
1. mm ; Operating pressure = 0.7 N/mm
2
; Maximum pressure when the
2
valve blows off freely = 0.75 N/mm ; Maximum lift of the valve when the CO4 3
pressure rises from 0.7 to 0.75 N/mm2 = 3.5 mm ; Maximum allowable
stress = 550 MPa ; Modulus of rigidity = 84 kN/mm 2; Spring index = 6.
Draw a neat sketch of the free spring showing the main dimensions.
2 A safety valve of 60 mm diameter is to blow off at a pressure of 1.2 CO4 3
 N/mm2. It is held on its seat by a close coiled helical spring. The
maximum lift of the valve is 10 mm. Design a suitable compression
spring of spring index 5 and providing an initial compression of 35 mm.
The maximum shear stress in the material of the wire is limited to 500
MPa. The modulus of rigidity for the spring material is 80 kN/mm2.
Calculate : 1. Diameter of the spring wire, 2. Mean coil diameter, 3.
Number of active turns, and 4. Pitch of the coil

Unit V BEARINGS

Q. CO’ Bloom’s
Questions Level
No s
1 How will you know the diameter of the bearing from bearing number? CO5 1
2. Classify the types of bearings. CO5 1
3 What are the required properties of bearing materials? CO5 1
4 What are the parameters required to select SAE oil for sliding contact CO5 1
bearing?
5 What are the types of journal bearings depending upon the nature of CO5 1
contact?
6 What are the types of journal bearing depending upon the nature of CO5 1
lubrication?
7 What is known as self – acting bearing? CO5 1
8 Write Mc Kee’s formula CO5 1
9 Write sommer field number formula CO5 1
10 Why is ball or roller bearing called antifriction bearing? CO6 1
11 Differentiate journal bearing and ball bearing CO6 1
12 When artificial cooling is required in sliding contact bearing? CO6 1
13 What do you mean by life of the bearing? CO6 1
14 Write the formula for equivalent load in ball bearing CO6 1
15 Write the formula for dynamic load carrying capacity of the bearing CO6 1
PART- B
The ball bearings are to be selected for an application in which the ra-
dial load is 2000N during 90 per cent of the time and 8000 N during the
1 remaining 10 per cent. The shaft is to rotate at 150 r.p.m. Determine CO6 3
the minimum value of the basic dynamic load rating for 5000 hours of
operation with not more than 10 per cent failures.

A single row deep groove ball bearing operating at 2000 r.p.m. is ac-
2 ted by a 10 kN radial load and 8 kN thrust load. The bearing is subjec- CO6 3
ted to a light shock load and the outer ring is rotating. Determine the rat-
ing life of the bearing.
A ball bearing subjected to a radial load of 4000 N is expected to have
a satisfactory life of 12 000 hours at 720 r.p.m. with a reliability of
3 95%. Calculate the dynamic load carrying capacity of the bearing, so CO6 3
that it can be selected from manufacturer's catalogue based on 90% reli-
ability. If there are four such bearings each with a reliability of 95% in a
system, what is the reliability of the complete system?
4 A rolling contact bearing is subjected to the following work cycle : (a) CO6 3
Radial load of 6000 N at 150 r.p.m. for 25% of the time; (b) Radial load
of 7500 N at 600 r.p.m. for 20% of the time; and (c) Radial load of 2000
N at 300 r.p.m. for 55% of the time. The inner ring rotates and loads are
 steady. Select a bearing for an expected average life of2500 hours.
A journal bearing is proposed for a steam engine. The load on the
journal is 3 kN, diameter 50 mm, length 75 mm, speed 1600 r.p.m.,
5 diametral clearance 0.001 mm, ambient temperature 15.5°C. Oil SAE CO5 3
10 is used and the film temperature is 60°C. Determine the heat
generated and heat dissipated. Take absolute viscosity of SAE10 at
60°C = 0.014 kg/m-s.
A journal bearing is to be designed for a centrifugal pump for the
following data : Load on the journal = 12 kN ; Diameter of the journal =
6 75 mm ; Speed = 1440 r.p.m ; Atmospheric temperature of the oil = CO5 3
16°C ; Operating temperature of the oil = 60°C; Absolute viscosity of oil
at 60°C = 0.023 kg/m-s. Give a systematic design of the bearing.
Design a journal bearing for a centrifugal pump running at 1440 r.p.m.
The diameter of the journal is 100 mm and load on each bearing is 20
7 kN. The factor ZN/p may be taken as 28 for centrifugal pump bearings. CO5 3
The bearing is running at 75°C temperature and the atmosphere
temperature is 30°C. The energy dissipation coefficient is 875
W/m2/°C. Take diametral clearance as 0.1 mm.
A journal bearing with a diameter of 200 mm and length 150 mm
carries a load of 20 kN, when the journal speed is 150 r.p.m. The
diametral clearance ratio is 0.0015. If possible, the bearing is to
operate at 35°C ambient temperature without external cooling with a
maximum oil temperature of 90°C. If external cooling is required, it is to
be as little as possible to minimise the required oil flow rate and heat
exchanger size.
8 1. What type of oil do you recommend? CO5 3
2. Will the bearing operate without external cooling?
3. If the bearing operates without external cooling, determine the
operating oil temperature?
4. If the bearing operates with external cooling, determine the amount
of oil in kg/min required to carry away the excess heat generated over
heat dissipated, when the oil temperature rises from 85°C to 90°C,
when passing through the bearing.

PART – C
Determine the dimensions of an I-section connecting rod for a petrol
engine from the following data: Diameter of the piston = 110 mm; Mass
of the reciprocating parts = 2 kg; Length of the connecting rod from
1. CO5 3
centre to centre = 325 mm; Stroke length = 150 mm; R.P.M. = 1500
with possible over speed of 2500; Compression ratio = 4: 1; Maximum
explosion pressure = 2.5 N/mm2
A connecting rod is required to be designed for a high speed, four
stroke I.C. engine.The following Determine the dimensions of an I-
section connecting rod for a petrol engine from the following data:
Diameter of the piston = 110 mm; Mass of the reciprocating parts = 2
kg; Length of the connecting rod from centre to centre = 325 mm;
Stroke length = 150 mm; R.P.M. = 1500 with possible over speed of
2500; Compression ratio = 4: 1; Maximum explosion pressure = 2.5
2 N/mm2 data are available. Diameter of piston = 88 mm; Mass of CO5 3
reciprocating parts = 1.6 kg; Length of connecting rod (centre to centre)
= 300 mm; Stroke = 125 mm; R.P.M. = 2200 (when developing 50 kW);
Possible over speed = 3000 r.p.m.; Compression ratio = 6.8: 1
(approximately); Probale maximum explosion pressure (assumed
shortly after dead centre, say at about 3°) = 3.5 N/mm 2 Draw
fully dimensioned drawings of the connecting rod showing the
provision for the lubrication.