Design of Machine Elements I

ASSIGNMENT QUESTIONS

10ME52

UNIT 1
INTRODUCTION
1. What are the factors to be considered for selection of material for a machine component?
2. What are the basic requirements of machine elements? Explain briefly.
3. Draw stress - strain diagram for mild steel subjected to tension. Explain the significance of
salient points.
4. Identify the following engineering materials giving specifications:
i) FG350.
ii) FeE300.
iii) C35Mn75.
iv) X20Cr18Ni2.
5. An unknown weight falls through 10 mm on a collar rigidly attached to the lower end of a
vertical bar 3000 mm long and 600 mm2 in section. If the maximum instantaneous extension of
bar is 2mm, what is the corresponding stress and the value of unknown weight?
Take E = 200 kN/mm2.
6. A point in a structural member subjected to plane stress is shown in Fig.Q.l(b). Determine the
following:
i) Normal and tangential stress intensities on plane MN inclined at 45.
ii) Principal stresses and their direction
iii) Maximum shear stress and the direction of the planes on which it occurs.

Department of Mechanical Engineering, SJBIT, Bengaluru.

Page 1

Design of Machine Elements I

7. Define Machine Design? Explain the importance of material selection in design?

10ME52

8. What are the advantages of malleable cast iron over white or grey castiron?
9. A standard alloy steel used for making engineering components is 20Cr18 Ni2. State the
composition of the steel.
10. List at least five important non-metals commonly used in machine design.
11. State at least 5 important mechanical properties of materials to be considered in machine
design.
12. Define resilience and discuss its implication in the choice of materials in machine design.
13. Discuss factor of safety in view of the reliability in machine design.
14. Suggest briefly the steps to be followed by a designer.
15. Define standards and codes.
16. Briefly explain the important mechanical properties of metals.
17. Draw stress-strain diagram for a ductile material and a brittle material and show the salient
points on them.
18. What is an adaptive design?
19. How are plain carbon steel designated?
20. Sketch and explain biaxial, triaxial and principal stresses.

Department of Mechanical Engineering, SJBIT, Bengaluru.

Page 2

Design of Machine Elements I

UNIT 2
DESIGN FOR STATIC AND IMPACT STRENGTH

10ME52

1. Explain the following theories of failure:

a. Maximum normal stress theory.
b. Maximum distortion energy theory.
2. A round stepped shaft is made of brittle material cast iron FG 260 and subjected to a
bending moment of 15 N-m as shown in Fig.Q2 (b). The stress concentration factor at the
fillet is 1.5. Determine the, following:
i. Step diameter.
ii. Magnitude of stress at fillet.
iii. Factor of safety.

b.
3. Derive an expression for impact stress in a bar of cross section' A' and length 'L' due to
the impact of a load 'W' falling from a height 'h' on the bar, as shown in Fig. Q2 (c).

a.
4. What is stress concentration? Explain the methods to reduce the stress concentration.
5. A steel rod of 40mm diameter and 200mm long, supported at one end is subjected to an
axial tensile load of 10kN at the free end. Determine the tensile stress in the rod.
6. A shaft is loaded by a torque of 5 KN-m. The material has a yield point of 350 MPa. Find
the required diameter using
(a) Maximum shear stress theory
(b) Maximum distortion energy theory. Take a factor of safety of 2.5.
Department of Mechanical Engineering, SJBIT, Bengaluru.

Page 3

Design of Machine Elements I

10ME52

7. The flat bar shown in figure is 10 mm thick and is pulled by a force P producing a total
change in length of 0.2 mm. Determine the maximum stress developed in the bar. Take
E= 200 GPa.

8. Find the maximum stress developed in a stepped shaft subjected to a twisting moment of
100 Nm as shown in figure. What would be the maximum stress developed if a bending
moment of 150 Nm is applied.

9. Derive an expression for stress induced in a rod due to the axial impact of a weight W
dropped from a height h on to a collar attached at the free end of the rod. What is the
stress due to suddenly applied load?
10. A steel rod 1.5m long resists an impact load of 2kN dropped through a distance of 50mm
along its axis. Limiting tha maximum stress in the rod to 150MPa, determine i) The
diameter of the rod required ii) Impact factor. Take E=200GPa.

Department of Mechanical Engineering, SJBIT, Bengaluru.

Page 4

Design of Machine Elements I

UNIT 3

10ME52

DESIGN FOR FATIGUE STRENGTH

1. Explain cumulative fatigue damage.
2. Derive Goodman's equation.
3. 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 20kN and a maximum value
of 50kN. Determine the diameter of bar by taking a factor of safety of 2, size effect of
0.85, surface finish factor of 0.9. The material properties of bars are given by: ultimate
strength of 650 MPa, yield strength of 500 MPa and endurance strength of 350 MPa.
4. A 60 mm diameter cold drawn steel bar is subjected to a completely reversed torque of
100 Nm and an applied bending moment that varies between 400 Nm and -200 Nm. The
shaft has a machined finish and has a 6 mm diameter hole drilled transversely through it.
If the ultimate tensile stress u and yield stress y of the material are 600 MPa and 420
MPa respectively, find the factor of safety.
5. Derive Soderberg's equation.
6. A portion of a connecting link made of steel is shown in figure The tensile axial force F
fluctuates between 15 KN to 60 KN. Find the factor of safety if the ultimate tensile
strength and yield strength for the material are 440 MPa and 370 MPa respectively and
the component has a machine finish.

Department of Mechanical Engineering, SJBIT, Bengaluru.

Page 5

Design of Machine Elements I

UNIT 4
THREADED FASTENERS

10ME52

1. 12 M20 x 2.5C bolts are used to hold the cylinder head of a reciprocating air compressor in
position. The air pressure is 7 MPa and the cylinder bore diameter is 100 mm. A soft copper
gasket with long bolts is used for sealing. If the tensile yield stress of the bolt material is 500
MPa find the suitability of the bolt for the purpose. Check if the joint is leak proof and also if
any joint separation may occur.
2. In a steam engine the steam pressure is 2 MPa and the cylinder diameter is 250 mm. The
contact surfaces of the head and cylinder are ground and no packing is required. Choose a
suitable bolt so that the joint is leak proof. Assume number of bolts to be used is 12.
3. Write a note on bolt of uniform strength
4. A Flange bearing as shown in Figure is fastened to a frame by means of 4 bolts, spaced
equally on a 500mm bolt circle. The dia of the bearing flange in 650mm and a load of 400
kN acts at a distance of 250mm from the frame. Determine the size of bolt, taking allowable
tensile stress in the bolt material as 60N/m2. Two dowel pins are provided to take up the
shear load.

5. A bolt is subjected to initial loading of 5 kN and final tensile load of 9 kN. Determine the
size of the bolt, if the allowable stress is 80 MPa and K = 0.05.

Department of Mechanical Engineering, SJBIT, Bengaluru.

Page 6

Design of Machine Elements I

UNIT 5
DESIGN OF SHAFTS

10ME52

1. What do you understand by shaft, axle and spindle?

2. What are the common ferrous materials for a shaft?
3. How do the strength of a steel material for shafting is estimated in ASME design code
for shaft?
4. What is an equivalent stress?
5. What are the limiting values of the angle of twist of a shaft?
6. What are the assumptions made to derive the equation for critical frequency? Why
critical frequency is important in shaft design?
7. Broadly, what are the types of bearings?
8. Highlight friction characteristics of bearings.
9. Prove that a hollow shaft is stronger and stiffer than a solid shaft of same length, weight
and material.
10. If a shaft and key are made of same material, determine the length of the key required in
terms of shaft diameter, taking key width and key thickness. Assume keyway factor as
0.75.
11. The standard cross- section of a flat key, which is fitted on a 50 mm diameter shaft is
16 x 10 mm. The key is transmitting 475 N-m torque from the shaft to the hub. The key
is made of commercial steel for which yield strength in both tension and compression
may be taken as 230 N/mm2. Determine the minimum length of key required if the factor
of safety is 3.

Department of Mechanical Engineering, SJBIT, Bengaluru.

Page 7

Design of Machine Elements I

UNIT 6
COTTER AND KNUCKLE JOINTS, KEYS AND COUPLINGS

10ME52

1. Design a typical cotter joint to transmit a load of 50 kN in tension or compression. Consider

that the rod, socket and cotter are all made of a material with the following allowable
stresses:
Allowable tensile stress y = 150 MPa
Allowable crushing stress c = 110 MPa
Allowable shear stress y = 110 MPa.
2. Two mild steel rods are connected by a knuckle joint to transmit an axial force of 100 kN.
Design the joint completely assuming the working stresses for both the pin and rod materials
to be 100 MPa in tension, 65MPa in shear and 150 MPa in crushing.
3. Two 30 mm diameter shafts are connected by pins in an arrangement shown in figure. Find
the pin diameter if the allowable shear stress of the pins is 100 MPa and the shaft transmits
5kW at 150 rpm.

4. A heat treated steel shaft of tensile yield strength of 350 MPa has a diameter of 50 mm. The
shaft rotates at 1000 rpm and transmits 100 kW through a gear. Select an appropriate key for
the gear.
5. Design a typical rigid flange coupling for connecting a motor and a centrifugal pump shafts.
The coupling needs to transmit 15 KW at 1000 rpm. The allowable shear stresses of the shaft,
key and bolt materials are 60 MPa,50 MPa and 25 MPa respectively. The shear modulus of
the shaft material may be taken as 84GPa. The angle of twist of the shaft should be limited to
1 degree in 20 times the shaft diameter.

Department of Mechanical Engineering, SJBIT, Bengaluru.

Page 8

Design of Machine Elements I

UNIT 7
RIVETED AND WELDED JOINTS

10ME52

1. What should be essential qualities of a rivet and its material?

2. What are the uses of snap headed, counter shank headed, conical headed and pan headed
rivets?
3. Two plates of 7 mm thickness are connected by a double riveted lap joint of zigzag pattern.
Calculate rivet diameter, rivet pitch and distance between rows of rivets for the joint. Assume
St = 90MPa, Ss = 60MPa, Sc = 120MPa.
4. How is a rivet joint of uniform strength designed?
5. Two mild steel tie rods having width 200 mm and thickness 12.5 mm are to be connected by
means of a butt joint with double cover plates. Find the number of rivets needed if the
permissible stresses are 80 MPa in tension, 65 MPa in shear and 160 MPa in crushing.
6. A plate 50 mm wide and 12.5 mm thick is to be welded to another plate by means of parallel
fillet welds. The plates are subjected to a load of 50 kN. Find the length of the weld. Assume
allowable shear strength to be 56 MPa.
7. Two plates 200 mm wide and 10 mm thick are to be welded by means of transverse welds at
the ends. If the plates are subjected to a load of 70 kN, find the size of the weld assuming the
allowable tensile stress 70 MPa.
8. A 50 mm diameter solid shaft is to be welded to a flat plate and is required to carry a torque
of 1500 Nm. If fillet joint is used foe welding what will be the minimum size of the weld
when working shear stress is 56 MPa.

Department of Mechanical Engineering, SJBIT, Bengaluru.

Page 9

Design of Machine Elements I

UNIT 8
POWER SCREWS

10ME52

1. Derive the equation for maximum efficiency of square threaded screw.

2. The C-clamp shown in figure uses a 10 mm screw with a pitch of 2 mm. The frictional
coefficient is 0.15 for both the threads and the collar. The collar has a frictional diameter of
16 mm. The handle is made of steel with allowable bending stress of 165 MPa. The capacity
of the clamp is 700 N.
(a) Find the torque required to tighten the clamp to full capacity.
(b) Specify the length and diameter of the handle such that it will not bend unless the rated
capacity of the clamp is exceeded. Use 15 N as the handle force.

3. A single square thread power screw is to raise a load of 50 KN. A screw thread of major
diameter of 34 mm and a pitch of 6 mm is used. The coefficient of friction at the thread and
collar are 0.15 and 0.1 respectively. If the collar frictional diameter is 100 mm and the screw
-1

turns at a speed of 1 rev s find (a) the power input to the screw. (b) the combined efficiency
of the screw and collar.
4. A weight of 500 kN is raised at a speed of 6 m/min by a two screw rods with square threads
of 50 x 8 cut on them. The screw rods are driven through level gear drives by a motor.
Determine (i) The torque required to raise the load (ii) The speed of rotation of the screw rod
assuming the threads are double start (iii) The maximum stresses induced in screw rod.
(iv) The efficiency of screw drive. (v) The length of nuts for the purpose of supporting the
load.
*************
Department of Mechanical Engineering, SJBIT, Bengaluru.

Page 10