DESIGN OF MACHINE ELEMENTS MODULE 1 2 MODULE 2 5 MODULE 3 21 MODULE 4 35 MODULE 5 67 MODULE 6 87 MODULE 7 126 MODULE 8 154 NOTE: MAKAUT course structure and syllabus of 6" semester has been changed from 2021 Previously DESIGN OF MACHINE ELEMENTS was in 5" semester. This subject has been redesigned and shifted in 6" semester as per present curriculum. Subject | organization has been changed slightly. Taking special care of this matter we are | Providing the relevant MAKAUT university solutions and some model questions & | answers for newly introduced topics, so that students can get an idea about university questions patterns. ‘|POPULAR PUBLICATIONS MODULE 1 Multiple Choice ce Qui lions 1. Steel containing carbon up to 1.5% is known as MWBUT 29, a) mild steel b) doad mild steel Tat ¢) medium carbon steel d) high carbon steel Answer: (a) 2. In case of clearance fit tolerance is (WeUT 29), a) unilateral for hole b) unilateral for both ¢) bilateral for shaft only d) none of these Answer: (a) 3. Stress concentration in cyclic loading is more serious in BUT 2055 a) Ductile Materials b) Brittle Materials ¢) Depends of other factors d) Unpredictable Answer: (b) 4. Von Mises’s theory is applicable for (wBUT 201 a) Ductile materials ¢) Elastic materials Answer: (a) b) Brittle materials d) all of these 5. According to Indian stan 200 means that the a) carbon content is 2% b) maximum compressive strength is 200 Nimm? ¢) minimum tensile strength is 200 Nimm? d) maximum shear strength is 200 Nimm? Answer: (c) dard specifications, a grey case iron designated by Fo [WBUT 20:7, 6. Resilience of a material is important, when it is subjected to [weuT 2013) a) combined loading b) fatigue ¢) thermal stresses d) wear and tear Answer: (a) Short Answer Type Questions 1. a) What is meant by ‘hole basis system’? 'b) A hole is dimensioned as 25,°) mm and the shaft is dimensioned as 2)" ' will Determine the hole tolerance and allowance of the fit. What type 7 Pee established? (wi DMET-2DESIGN OF MACHINE ELLIE! 1 ever! : tole basi SYST pre the hol ay Het mit system where the hole is as a constant 115 MF means when the lower deviation of the hole is jz ote Mgitferen fits are obtained by varying the | zen) type of limit system is called hole ! [iM ty size. This orig system. wes 3st a Hole Hass y civen dat oer limit of hole = 24.97mm tamer imi of shaft = 25.03mm rr lit of shaft = 24 98mm Jpper limit of hole - Lower limit of hole 25.03 - 24.97 = 0.06mm [Ans. (i)] allowance ofthe fit = Lower limit of hole ~ Upper limit of shaft = 24.97 -25 =-0.03mm [Ans. Lower limit of the hole < Upper limit of the shaft Then it will establish transition fit. ole tleranct i) 2, Athin cylindrical pressure vessel of 500 mm inside diameter is subjected to mal pressure of 2 MPa. If the thickness of the vessel is 20 mm, find the hoop iter firess and longitudinal stress, (WBUT 2015] ‘Answer: Given data: 4 =500mm p=2MPa=2N/mn? 1=20mm Hoop stress, 0, a = 2 =25 N/mm? =25Mpa [Ans. (i)] Longitudinal stress 50 SO ons Nimm? =12.5 Mpa [Ans. (ii)] 3. What do you understand by the following designations of steel? [WBUT 2017] a) Fe 320 ) FeE 200 ) 40c8 4) 30Ni6Cr5 ©) X15Cr25Ni12 Answer: 4) Fe 320 + ‘Fe 320° means a steel waving minimum tensile strength of 320N/m’ b) Fe E 200 — ‘Fe E 200° means a steel having yield strength (minimum ) of 200 N/mm* ©) 40C8 — *40C8" means a carbon steel containing 0.35 to 0.45 percent @Nerage) carbon and 0.60 to 0.90 percent (on an average 0.75 percent) DMET-3pe ‘% carbon, 40, \; 4) 30Ni16Crs _, “30Ni16CrS* mean alloy steel having average 0.3% carbon Nig, and 1.25% Chromium, ith average carbon 0,15 ©) X1SCr25Ni12 — «x | PC2SNi12*- means alloy steel with average c Per coy chromium 25 percent and nickel 12 percent |DESIGN OF MACHINE ELEMENTS MODULE 2 SELE 2 Multiple Choice Type Questions + Maximum shear stress theory is applicable for [WBUT 2009, 2012, 2018, 2019] 2) ductile materials b) brittle materials ¢) elastic materials d) all of the: Answer: 2. A basic shaft is one whose a) lower deviation is zero c) upper deviation is zero [WBUT 2010) b) lower and upper deviations are zero 4) none of these Answer: (c 3. Principal stress theory of failure is applicable for [WBUT 2011] 2) Ductile materials b) Brittle materials c) Metals 4) Composites Answer: () 4. The property of a material which enables it to resist fracture due to high impact joad is known as [WBUT 2013, 2018] a) Elasticity b) Endurance ¢) Strength 4) Resilience Answer: (¢) 5. Ifa shaft made of ductile material is subjected to combined bending and twisting moments, which of the failure theory would give the conservative value? [WBUT 2013] 2) Maximum principal stress theory b) Maximum shear stress theory ¢) Maximum strain energy theory d) Maximum distortion energy theory Answer: (b) 6. Von-Mises theory of failure is used for [WBUT 2014) a) brittle material b) elastic material ¢) elasto-plastic material 4) ductile material Answer: (2) 7. For design analysis for long column [WBUT 2015, 2016] a) Johnson's equation is suitable b) Rankin’s equation is suitable ¢) Euler's equation is suitable d) Both (a) and (b) Answer: (c) §. The design of shafts made of brittle material is based on [WBUT 2015] a) Guast’s theory b) Rankine’s theory ©) St. Venant’s theory d) Von Mises theory Answer: (b) DMET-SPOPULAR PUBLICATIONS (WBUT 2017, ay be increased by rr 9 Resilience of a DO MAY Tig 1) increasing Its c is “ dial ing its 10 oj oor "0 ite shank aiareter ©) docre i 4) decreasing Its ena TAT Answer: (1) itable to predic! failure jure (6 9 [WBUT 201 tnoory of a tito mate! 7) 40, Maximum duterion energy fi ampostt® material 1) brittle mat c) plastic mate Answer: ()) noory of Failure ; - 4a) State Maximum stat ny of Fal ygirections a0 7, = 200MP, b) ina bi-axial strass Pl tress and maximum sh Toy MPa.. What (8 the maximum principal str lear pea [WBUT 2019} stress in MP2 amet tress Theory of Failure Maximum Shear Stress . . the failure ‘occurs at a point in a point in a body when the maximum shear stress in a bi. nial stress system reaches @ value equal to the shear stress at yield point in a simple tension test Mathematically Tan =Ty/ FS. ay, = Maximum shear stress 1, =Shear stress at yield point FS = Factor of safety. b) Given data ©, - 200 MPa, 0, 100MPa a 45 “c0s20=0 sin 20=1 9-9, Maximum principal stress, 2 70820 _200+100 200 = 200+100 | 200-100 27> =150 MPa Maximum sh o, Soar stress = 22= 8 yr sin29 = 200-100 o T=30 MPa DMET-6> at is factor of safety? Define factor of safety for brittle and ductile materials DESIGN OF MACHINE ELEMENTS go you mean by endurance limit? Define fatigue lite [WaUT 2012) ewer a ctor of safety: or easure of safety of material, It is defined as the ratio of the maximum stress to the working § Maximum stress Factor of safety ie a Working as design stress sor ductile materials, the yield point is clearly defined, the factor of saety is the ratio of Ip sel paint stress to the working stress Fy brittle material the yield point is not well defined, so, the factor of safety ig the ratio of the ultimate stress to the working stress for brittle material Endurance limit the value of the stress for any material after which the material will not f te the number of cycles. It is represented by dotted line. It is denote by (2) fail whatever may = Noofeyels > 3. Stresses induced at a critical point in a machine component made of steel 45C8 (c, =380 Nimm*) areas follows 0, =100 Nimm’,o, =40N/imm? and _, =80N/mm*. Calculate the factor of safety by [WBUT 2012] (i) Maximum normal stress theory (i) Maximum shear stress theory. Answer: Given data: , =100N/mm* 6, =40 N/mm? op = 380N/mm 1, =80 Némm? Maximum normal stress W440 100-40) : 1 100 + 40 | 100 0) + (80) 7 Wo2)POPULAR PUBLICATIONS [(30)' + 80)" = 155.44 Némm’? 04 Minor normal stress = 18 (100-40) egy 15.44 Nim’ 2 Wo2 ) Maximum shear stress oO, -9, 155.44 (15.44) 5 85.44 Nitnm? Maximum normal stress, 6, ce 380 Fas FS=244 [Ans.(i)] 155.44 According maximum shear stess, tay, =ty/ 2x FS or, $5.44= 380 xFS FS.=2.22 [Ans. (ii)] 4. A flat plate subjected to a tensile force of 5 KN is shown in figure below. The Plate material is grey cast iron FG200 and factor of safety is 2.5. Determine i. thickness of the plate. Assume K,=1.8 corresponding to Djui—| sang r/d =0.167 and K, =2.16 corresponding to d/w=0.5 [WBUT 2013 vs T3a} 4% 30-OF Fea “or SKN Answer: Given data W=SKN=S-10°N; d=15mm 4 =45mm b, = 30mm Let, thickness of the plate = For wide pan, Nominal stress = _ 5410! _ S10" A bet 48x DMET-8y- DESIGN OF MACHINE ELEMENTS 10 Maximum stress = K, x Nominal stress = 1.8 sqrow part, A=(P, dV = (30-18 =154 W S~10) wominal F085 = = yoni stress = K, x Nominal stress = 2.16921 seahe plates of same material al along For fillet part Sx10? Nominal stress = >=" (axF 2 seximum stess = K, x Nominal stress = 21,8 2210 *2 ax25 5x10? 5x0? 2] sx10° 5x10 2) 216[ 18 xr 9x25 1Sxt 5. A forged steel bar, 50 mm in diameter, is subjected to a reversed bending stress of 250 MPa, The bar is made of steel 40C8 (S,; = 600Mpa). Calculate the life of the bar for a reliability of 90%. Assume Surface finish factor = 0.44, Size factor = 0.85, Reliability factor = 0.897. (WBUT 2016) Answer: Given dat d= 50mm =0.05m o, = 250 MPa = 250N/mm? o,, = 600 MPa = 600N/mm* K, =0.897, K, =0.85, Ky = 0.44 Fatigue strength S, =10° N“ 97 x a=—dog 2# = ign 600 ott o, 3 250 c= be 22k 064 Oo, DMET-9a POPULAR PUBLICATIONS Nimm cycles following data. a shaft a8 per AS. ME. based on the I Toraee end bending moments applied are 450 N-m and 100 N-m respective), i) The load is applied with light shock. For this case the combines sh Pi . Ok an fatigue factor applied to bending moment, £, -|.Sand the combined Shoon we fatigue factor applied to torsional moment, i = |. , d fil) The shaft material is having ultimate strength of 440N/mm yield Strengt Nimm’ and elastic limit of 250 Nimm?, Maximum Shear stress, - h OF 35 0. “18S, (whichever is minimum). There is no keyway in the shaft. DWBLT 2, Answer: Given Data T=450N-m; M=100N-m K,=15; K,=10; o, = 480 Nimm* ¢, = 310 Nimm?; = 250 Nimm? 30S, or, 0.185, —— (K, *M} +(K, 1p = = 0.188, =86.4 Nimm? = V(1-5%100)' +(1x450)° = ; z 5110 =A xd 186, 16 ‘ 4=03=1mm Answer: Given, W= 1009 ky 4= 250mm 7, = BOMPy = First of (weuT 2017, 1000.10 y 80 Nim? all lt the pressure es (4) Pressure inside the cylinder (p) that load on the hydraulic low ig)> DESIGN OF MACHINE ELEMENTS 100010 Po 4g.tvl0 0.47 N/m wide radius of the cylinder 4 pet, 7,» inside fi he cylinder = d/2- 125mm, the wall thickness of the cylinder, | 1 {mm mio, | go12037 | 1251 «| “1mm \\so 20.37 | 125(1.297- Imm 37mm 4, Amachine member 0.05 m diameter and 0.26 m long is supported at one end as cantilever. The arrangement of load on the member is shown in Figure below. Determine: i) Maximum principal normal stress, and ii) Maximum principal shear stress. [WBUT 2015] 2750 250.Nm A + 13.75KN Ss 0.05m rc Np rr Answ Given data: W =2750N T = 250 Nm = 250 *10° N ~ mm P=13.75KN = 13750N d= 0,05m = 50mm x= 0.25m = 250mm Aa Fed? = 1964 mm? Tensile stress due to axial falling at points A and B of 13750 | = 7 MPa A 1964 DMET-11POPULAR PUBLICATIONS Rending moment at points A and A : " eM Wy © 2750 250 - 687500 Nomm » 6885 KN mm Section modules. < (50)" = 13.2710" mom! 2 2 Bending stress at points A and 1 O&K 5» 10! 7, = PRR S IO cy Aang 2 12.27%10" This bending stress is tensile at point A and compressive at point B, Resultant tensile stress at point A 4 = 9,40, = 56.1147 63.11 MPa and resultant compressive stress at point B, 9) = 0, -0,=63.11-7 = 49.11 MPa Shear stress at points A and B due to torque transmitted p= 167 _16x1x10° nd’ (50) At point A, Maximum principal normal stress Fon Sa ey eae 3. ——__. = on % 63.11) +4«(40— 74)? = 83.08. (tensile) (Ans. (i)] Maximum shear stress 1 Fame) = 5M(0,)' +45? =51.53 MPa [Ans, (iy) At point B, = 40.74.N/mm? = 4574 Mpa Vo, var? bean) 49. > +9. Faxca0 -74)? 5 mi MPa (compressive) [Ans, (i) Times = 5 Moy)? +47? 8 in all leaves of a ‘multi-leaf spring is, %, =6PL/nbt’. [WBUT 2016) B 4 single pla \ Plate fixed at one end and loaded at the other end DMET-1)DESIGN OF MACHINE. = Thickness of plate ot Let width of plate J = Length of plate i - aximum lending movement at A f Maxim i— lk section modulus, Z = = DN2 lye s y 2 6 4 ending-stress in such a spring OE 2 Lape oF 6 ifthe plate of cantilever is cut into a series of units of width b and these are placed like the figure 6Pl nbt 3, A rotating shaft subjected to a non-rotating force of SkN and simply supported between two bearings A & E as shown in fig. 1. The shaft is machined from plain carbon steel 30C8(S,, =500N/mm*) and expected reliability 90%. The equivalent ife of shaft? radius at the fillet section can be taken as 3mm. What i notch SiN [WBUT 2046, 2019] \<— 300 eres, 200 —>| Answer: Given Data D=45 mm d=30mm a, =800 N/mm? r=3mm K, = 90% =0.9 Did=1 rid=.1 From standard value for D/d and r/d K, =1.84 [K,= theoretical stress concentrati :. Bending moment at fillet portion M' =K xM =1.84« 5000 x 400 = 3.68 10° N-mm ion factor] DMET-13POPULAR PUBLICATIONS Section modult 2.6510" mm’ ection modulus Z Bending stress 1.3810" Nimm’ Forr=3 gel x A, Now for steer o, = 0.5 0, = 250 N/mm? KK, =1.38% 10! x 0.91.84 6, = 2.2810" If life of shaft N cycles Oy =10°N" p24 = 0.07 c=log| 24) |=3.58 % o, =10" NO or, 2.28x10° =10°* NO” N=1.48x10° Cycles [Ans.] 4. A steel cantilever is 200mm long (Fig). It is subjected to an axial load whisy varies from 150 N in compression to 450N in tension and also transverse load st. free end which varies from 80N up to 120N down. The cantilever is of circus, cross-section. It is of diameter 2d for first 50 mm and of diameter d for tu remaining length. Determine its diameter at the fillet cross-section taking a facts of safety of 2. Assume the following: Yield strength = 330 N/mm? Ye say Ultimate strength = 600 Nimm? t Stress concentration factor = 1.44 for Row bending & 1.64 for axial loading 2d foe iain Ft Surface finish factor = 0.9 Size factor = 0.85 Reliability factor = 0.897 Notch sensitivity factor = 0.9 Endurance limit of standard specimen in axial loading = 0.8 times the endurantt ‘imit of the standard rotating beam specimen in reversed bending. (WBUT 20t8] Answer: Given Data (=200mm Winans = 450N DMET-14DESIGN OF MACHINE ELEME 140N 120N We scant RON OMPa . 600 MPa © 600 Nim 90.7. Kyl Ky Tad, K, O85 Kk, 09 qe 09 400.4 (150) pean vial load. hy , sort W mas) W, 5 rable axial load. WF, wim) _ 450 a 300N W, 150x419) ean axial ste88, 0 = == = Nim? A d W, 3004 382. \ariale axial se, 0, == = Némm We know that fatigue stress concentration factor for revered axial loading. Kya 14 Ky 1)=140.911.64~1)=1.576 and endurance limit stress for revered axial loading o,, ~¢,*K, = 600/2%0.7 = 210 N/mm? We know that equivalent normal stress at point A due to axial loading, o,40,*Ky _ 191, _382%330x1.576 ad? d?x210x0.9x0.85 Oy = Int +. = ay Ke ® Koa 191 1237 _ 1428 N +e a a mm? Now, Hm) 2 120 -(-80) -100N 2 W nn; Ban, 120480) 99 Mean bending load, M7, Variable lending load = Mean lending moment at point A M,, =W,(E-~50) = 20(200 ~ 50) = 3000 Variable bending load M, =W ,(¢~50) = 100(200 ~ 50) = 15000 N-mm N-mm DMET-15POPULAR PUBLICATIONS 7 A 009K2d mi Monn lending st 4 win 080 a, ‘, mu Ninn’ a 4 OK ad Variahle bending stte M 14000 142740 4 Mion "7 00K a Fatigue stress concentration factor for reversed fending Ky Veg ky WV O90 AA Wy 1496 Endurance limit per reversed lending, | 20 oo Crs oy 2025 Nn J quivalent normal stress at point A due to lending, 4O,7K, W550 V5 507 990 /1.996 ‘ Ont Kig ZK, did? 2025/0972 0.85 30550 | 350420 480970 jl i ron’ d d a Total equivalent normal strexs at point A 380970 Dug Fa ¥ One ney a Mimmn* ded o 330 Peon 165 Nim? F, 9 er eee A 1428 165 d a 380970 + 142d = 165d" 266.784 d = 0.116d" d= 13.3 mm [Ans.| 5. The work cycle of a mechanical component subjected to completely reversed cyclos, a) 350 Nimm’ for 85% of time bb) £ 400 Nimm’ for 12% of time ¢) # 500 Nimm’ for 3% of time The material of the component 60C4 (Sut = 660 MPa) and corrected endurance limi of the component is 280 Nimm’. Determine the life of the component. [WBUT 2019] DMET-16> answer viven data DESIGN OF MACHINE ELEMENT 660N/mm? 6, = 280N/mm? 7 mm GN Diagram construction * oy = 0.9% 660= 594 Nimm? (0.90,) 108 (84) = 2.7738 (c,) = !o8io(280) = 2.4472 jog (0) = ogy. (350) = 2.5441 Jogo(%) = Jog). (400) = 2.6021 Jog(9) = Jog, (500) = 2.6990 prom ewe Dax AE _ (6-3)(2.7738- logo) pe ane) AD (2.7738 - 2.4472) _, FF =9.1855(2.7738 —lo8.0) N=3+EF logy N =3+9.1855(2.7738— log. 2) Now, for case (a) Togig Ny =3+9-1855(2.7738— 2.5441) = N, =128798 For case (b) Jog, N; =3+9.1855 (2.7738 - 2.6021) = N, =37770 For case (c) log, Ny =3+9.1855 (2.7738 2.6990) = N, = 4865 Now, m, =@,NyM, = Noms Given, a, =85% = 0.85 a, =12% a, = 3% = 0.03 Modified Miner's rule log, S, log logic Also, 10810 aN dL 0.85 eo 0.12 4 203 “N 128798 37770 4865 +. N= 62723 Cycle {Ans.] DMET-17POPULAR PUBLICATIONS 6. Briefly discuss different criterion of failures, Answer : wy, Various Theories of Failure Toy, 1. Maximum Principal Stress theory also known as RANKINE * 2. Maximum Shear Stress theory or GUEST ANIp TRESC Ass pL HEORy 3. Maximum Principal Strain theory also known ae <° Vi NAS TH ORY 4. Total Strain Energy theory or HAIGH'S THF y 5. Maximum Distortion Energy theory or VONMtSn SAND HE NCK y's T Rankine St Venant (0.35) Haigh (0-035) + Castiron © Copper Steel Aluminum 1. Maximum Principle Stress Theory: This theory was proposed by WIN Rankin. This is one of the oldest and 9, = 5, or, =S, 1s considered as the best theory of failure ductile materials under the following state of sirss The condition of the failure is, Maximum principle stress theory materials, but it is also suitable fo: conditions: Uniaxial state of stress condition only Bi-axial state of stress condition whet © is neglected because of unlike nature. Hydrostatic state of stress condition ie., for brit n principle stresses are like in nature. He? when oo, DMET-18DESIGN OF MACHINE LLEMENIS 1 Representation, ni oe re cepresents the stale of stresses under this theory, Square is divided into four fants 1c first quadrant both oy and a)are positive or tensile in nature. In second va si €. compress Hh ant oy U8 NeBatIVe Le. Compressive in nature and «is positive. In third quadrant beth qu Saiivali imal apare neative ie. compressive nature anvl in last ie, fourth quadrant is ovate and opis nepative. The maximum principle sess sequal to the elastic limit of imetrariat and the material will reach its elastic limit when the stresses (ayand 94) Ho susie ve square oximum Principle Strain Theor igs theory also KnOWN as Saint Venant’s theory. According to this theory, the ductile aerial starts yielding when the maximum principle strain reaches at that value at which imaing occurs in simple tenvion or we can say thatthe minimum principle strain value is ‘ral tothe yield point strain in simple compression, ‘This theory isnot suitable forthe ie materials because it gives over safe dimensions of the ductile material The design equation according to this theory is, a, -m(o,ando;)<5,, 2 Graphical Representation: Th shape of the diagram according to the principle stresses is like a Rhombus which is symmetrically placed with respect to the axis. The sign of stresses is same as the previous theory but the shape of diagram is changed. 3, Maximum Shear Stress Theory: This theory was proposed by Coulombs and Guest. According to this theory the failure of any mechanical component occurs when it is subjected to bi-axial or tri-axial stresses and then the maximum shear stress at any point of the component reaches up to the value which is equal to the maximum shear stress in the standard specimen of the tension test when yielding is start. In the tension test the specimen is subjected to the uniaxial state of stress i. , =. So the maximum shear is equal to the half of the difference between the maximum and minimum principle stress. Therefore the maximum shear in simple tension is equal to the half of the tensile stress. Design equation of maximum shear stress theory is Absolute 7, =5, oF (0, ~o 2-8, ‘This theory is not svitable for ductile materials because it will give over safe design for ductile components. This theory is not applicable to materials subjected to hydrostatic state of stresses, in this case shear str almost zero which means the failure in the material will not occurs which is impossible. Graphically a Hexagon represents the stress distribution which shows that the materials will reach its clastic limit when the stresses (9, and o,,) go outside the region. DMET-19POPULAR PUBLICA 4. Total Strain Energy Theory: This theory was given by Beitrami Haigh’s. Accor components under the complex stresses fails when on. This theory states that,’ equal to the strain energy at elastic limits in simple feN8i0%. Taine of these Stre material deformed permanently due to the various str that the initial strain eng increase gradually from zero value due to this we ca $2), ey independent of the nature of stresses and is almost consta The design equation according to this theory is 03 ~2u(o,9, +949, +850;) = (51) this theory the engin, ding to UIs, i eri re total strain energy in the jy oro: - who A This theory is applicable for those brittle materials entation of this theory is show, and compression are different. The graphical repres' The material mechan: the Ellipses which are inscribed by the ree ed g,) fall outside the ein. component reaches its elastic limit when the stresses (2) : has elastic limit stress in ten, . Maxi Stress Energy Theory: . This theory The Mery is alse leven as the maximum distortion Sea aetion given by M.T. Huber and R. Von Mises. ae ET when the stain a int in the engineering component starts due to various train By of distortion re Unit volume is absorbed at a point is canal oe ae in we d distortion absorbed per unit volume at any point in a bar ic limit under the uniaxial state of stress in the simple tension or Peer test. So we can say that the part of the strain energy produce change in the shape of the element i supposed to be completely responsible for ‘he failure of the material by yielding. This theory is considered as the best and safe among all the theories for designing an, mechanical component. . : ‘The design equation according to this theory is, (a\-«)' +(o,-0)' +(0, -0,)' =2(S,) This theory is not applicable for the brittle materials for which elastic limit stress is different in tension and compression. This theory is also not applicable for hydrostatic state of stress conditions. The graphical representation of this theory is same as the tota strain energy theory, both are Tepresented by the Ellipse and the Stress variations are also same.Multipi — Catsipte Chotes Type guestons ne property of a material 7 vat which enables it to resist fracture due to high impact ae 2) Elasti Endurance ABUT 200 ee e ©) Strength 4) Resilience , Tne oe ar ond carrying members which carry we "i }UT 20107 ee ») compressive toads y pe (c) ) torsion loads. 3. Endurance limit is determined by a) the rotating beam method [weuT 2013] b) static loading in universal testing machi ¢) static loading in torsion testing machine” @) any one of these Answer: (a) 4, Stress concentration is caused due to [weuT 2019] ber a) variation in properties of material from point to point j b) pitting at points or areas at which loads on a memeer ane ened c) abrupt change of section d) all of these Answer: (d) 5. Pick up wrong statement. Fatigue strength can be increased by a) cold working b) short peening c) grinding and lapping surface d) hot working Answer: (b) [WBUT 2019) estions Short Answer Ty] 1. With the help of a figure, briefly explain how Goodman diagram and Soderberg diagram are used for fatigue design of a component{WBUT 2012, 2015, 2016, 2018] OR, [WBUT 2019] Explain modified Goodman diagram. Answer: Goodman diagram A Goodman line is used when the design is ba strength and may be used for ductile or brittle materials. ed on ultimate strength on ultimate DMET-21POPULAR PUBLICATIONS As shown in the Goodman diagram a straight line connecting the enduranc € limit (a) and the ultimate strength (o,) Line AB connecting a, and a, is called Goodman's failure stress line, factor of safety (F.S) is applied to endurance limit and ultimate strength, a safe StreSs Jin, may be drawn parallel to the line AB, Now, taking a design point P on the line ¢ D Now from similar triangles C OD and P QD 22 9D oD-o 199 = = SE “OD = OD ~Or cO ob oD om ©e 2) Now, a Suita),- DESIGN OF MACHINE ELEMEN F snpecting the endurance limit (or,) and yield strength (a) as shown In ‘ wet Xt Soderberg’s fhilure stress line. Now suitable factor of safety (F.S.) Ato the endurance limit and yield strength, a safe stress fine CD may be drawn yo the fine AB Now, considering a design pont Pon the fine CD. New from iat grianges COD and POD. ‘ YD OD-09 coo oD Ow (0D- 0D 09) ting bar of steel 45C8 (Sy. = 630 Nimm’) is subjected to a completely 2. A rotat ending stress. The corrected endurance limit of the bar is 315 Nimm. Taeulate the fatigue strength of the bar for a life of 90,000 cycles. [WBUT 2014, 2015, 2018] Answer: Given data: 9s, = 0.9630 =567 N/mm? 0.98,,) = log,, (567) = 2.7536 Bio (315) = 2.4983 ege(S Jog,- (90000) = 4.9542 log,, (10°) =3 log, (10°) =6 Fatigue strength DMET-23o withstand a tensile preloag (0 to 72.6 KN. The bar has g o1 83, a fillet whose radius jg'g Mey," f 2. radius ig 49 n factor of 702 ctgue loading ay = 0.96. Determine the ni275 nt “Kg factor of safety of 2. Assure Cr = 0.73 tere oF) trator, G, = 0.88 for load factor under axiay ruta! The material properties are S, = 588 MPa, st any un 9nt aay 2046 isto be designed t loads 9 from varyin 02 corresponding to Size g igh factor. c, i oe a ana for (99% reliability. wre Anewer Given date p= 363KN; Wy W,,, =TL6KN; K, oss 073: C, 095; C,=0.85; Cy = 0814 3g, =350Nimm? ps=2. C, = 588N/mm’?; o, = 700 Nimm'; og, = 0.5 =14.9,(K, 1) =1+0.95(2.02 -1) = 1.969 From concentration factor K, Let. d= Diameter of the rod Variable stress, 0, = A 4 ‘According to Saderbery’s formula a oxK, FS 0, xC; XC; XC, XCy i S4AS/A 54.45) Ax1.969 2 588” 350x0.73x0. Cee .95x0.85x0.814 Aad on 146-2 ed 4 4=43.11mm [Ans] DMET-24, Acal DESIGN OF MACHINE ELEMENTS ntitever beam made of cold drawn steel 20C8 ( 5, = 540 MPa) is subjected to completely reve ed load of 1000 N as shown in Fig. The theoretical stress ebentration factor Is 1.35, notch sensitivity factor is 0.85 and the expected mpility 1s 90% (Corresponding factor X, ~ 0.897). Surface finish factor Is 0.78. reli petermine the diameter 7 of the beam for a life of 10000 cycl (WBUT 2015) +100 —1000N answer: Similar to Question No, 2(a) of Long Answer Type Questions. 5, Amachine component is subjected to fluctuating stress that varies from 40 to 400 MPa. The corrected endurance limit stress for the machine component is 270 pa, The UTS and Yield strength of material are 600 and 450 MPa respectively. Find the factor of safety using Gerber theory. [WBUT 2017] Answer! 401100 sine? = 70 Nim? ‘N/mm? = 30 Nimm? oF 100-40 2 Using Gerber theory 2 ot -0.0136% F.$.+0.112 FS. 30.0136F.S? +0.1112F. 3 0.0136F.S? +0.112F.$.-1=0 =4x0.0136(-I) _ -0.1112+0.2584 2x 0.0136 20.0136 >FS.=5.41 ~ Factor of safety using Gerber theory is 5.41 DMET-25os itivi i &. What do you mean by ‘notch sensi Wat te ©encentration factor. 2 Answer: Notch sensitivity: cyclic loading. It may be defin, Ie ferm notch sensitivity i aplied ie a chet “hich the theoretical effect of stress Saisie increase of actual stress over nom — a OF actual se inal stress increase of theoretical stress over nomin k=l POPULAR PUBLICATIONS ty’? Find the relation of i led a8 the deg, ee notch J = notch sensitivity k, = fatigue stress concentrated factor &, = theoretical stress concentrated factor 7- A shaft is subjected to altemating stress 125 MPa. Fatigue strength to us, a 1000 cycle is 450 MPa, Determine the life of the shaft for the corrected enqu 4 y ; Meg ‘strength of 80 MPa. MMBUT 204s} Answer: A{3,log,,(450)} B{6,108,,(80)} F {log,, N,log,,(125)} CE DE AE AD ° logpN-3 6-3 ‘ © Toe (450) =T0g, (125) 18 9(450)— To, 80 + 3 3 ogi vlogy, N= 5: +N =173780Cycles [Ans.] 8. Derive the expression of Miner’s equation for finding the service life of enacting element fails due to cumulative damage. [wBUT Answer: Act Miner’s Rule: Miner’s rule is probably the simplest cumulative damage model. It st that if there are k different stress levels and the average number of cycles to failure @ ‘th stress, S, is N,, then the damage fraction, C. is: DMET-26DESIGN OF MACHINE ELEMENTS: yt ec a Whe isthe number of cycles accumulated at stress S, ye the fraction of life consumed by exposure to the cycles at the different stress Jevels. In general, when the damage fraction reaches 1, failure cours spe above equation can be thought of as assessing the proprtion of ie The ares level and then aking the proportions forall the tevels together, Often an cer for quantifying the damage is defined as the product of stress and the number of igs operated under this stress, which is W=nxS, ming thatthe critical damage isthe same across all the stress levels, then W, Q) fatee Te. let’s say Wrajue=50 for a component. So the component will fail a level of 5, of after 25 cycles to fail at a stress level of 2, and so on he critical value of damage that will result in failure, Eqn. (1) Ass XS, - fter 10 or exampl cycles at @ StTeSS Using Eqn. (2) as tl pecomes: ‘ s Ln xS, daxs, ya =C2 c...@) represents te proportion ofthe cumulative damage tothe critical value. Long Answer Questions 4. Find the stress: at the inner and outer surfaces of section A-A of the frame [WBUT 2010} shown in Fig. if the force F = 2200N. [All dimensions are in mm]POPULAR PUBLICATIONS Answer: Given data W=2200N b, =20mim b, = 10mm h= 40mm R =50mm R, =50+40=90mm We know that area of section A ~ A 4 ={.c0+10)»40= 600mm! Radius of curvature of the neutral axis b+, } h 2 --8) TE (S-0-» 20+10 M a 70x90 -10x50 %). 20-10) ans (5) and radius of curvature of the centroidal axis, pep + HAABB) 594 M020#2419) _ 67.75 mn 3,+8,) 3(20+10) Distance between the centroidal axis and neutral axis, e=R-R, =61.18- 65.91 =1.87mm and the distance between load and centroidal axis, x =100+R=100+67.78 =168.78mm . Bending moment about the centroidal axis, ‘M=W.x=7200%168.78 =371316N — mm Lind ein oa ‘ ~ A is subjected to a direct tensile load W = 2200N and a bendine ofM= we a We know that direct tensile stress at section A — A one 1 ig 73:67 MPa = 65.91 mm DMET-28DESIGN OF MACLIINE ELEMENTS a . meee: - et ' | oe ’ t | \ lett ole! ' |ole! — my ' hele ‘ \ \ f | ' ' ' 1 | AON i, i ’ le" >| Ie X. >| le " >! < t —>| ance form the neutral axis tothe inner surface y RR = 6591-50 = 15.91 mm ¢ from the neutral axis to the outer surface y, RR, 9065.91 = 24.09mm We know that maximum bending stress at the inner surface M-y, _ 371316x15.91 tee 600%1.87%50. J maximum bending stress at the outer surface. —~ ae = 159,47 N/mm? =159.47 MPa (compressive) Resultant stress on the inner surface 3G, +.0,, = 3.67 +105.305 = 108.97 MPa (tensile) [Ans. (i) and resultant stress on the outer surface 6, ~ Oy =3.67 -159.47 = -155.8MPa =155.8 MPa [compressive] [Ans. (i)] Dist pistane 105.305 N/mm? = 105.305 MPa (tensile) 6 and re ss-section as shown in Figure below is made h factor of 0.78 and ultimate tensile to completely reversed bending load factor and reliability factor are given he diameter of the beam for a life of 2. a) A cantilever beam of circular cro of cold drawn steel having a surface finis! strength of 540 MPa. The beam is subjected of +1000 N. The fatigue stress concentration as 1.2975 and 0.897 respectively. Determine tl 10,000 cycles. 4 : I: coo ) Briefly explain what are the meant by alignment and misalignment of the shaft. [WBUT 2013) DMET-29> POPULAR PUBLICATIONS Answer a) Given data K, = 1.2975 K, - 0.897 Ky, 0.78 0, ~ 540 MPa ~ 540, N/mm Endurance limit 0, = 0.50, = 0.57540 270N/mm’ Let, diameter of the beam = d Pro, = 1000N Pq =-1000N (compressive) 1000 am ad’ M -1000 Minimum stress 0,,,=—>—— xd’ i 000 + (—1000) Mean stress g,, = Sma Sma = [ror 0.50, Maximum stress o,,, Variable stress o, 1000 N/mm? Oy XK, oO, 0,xK,xK, I Applying Goodman relation, —_ ‘Pplying Goodman relation, Fs Let, F.S = Factor of safety = 2 10 1000x 1.2975 ogee => 2 540 210% 0.180.897 7) xd? or d 294. 1000 «1.2975 x 4 2100.78 x 0.897 x nx d? ds 1000%1.2975% 4x2 Toe a7, 2700.78 0.897 x > '7-49 4=4.18% 5mm [Ans,| ») Alignment of shaft; v entte lines of two shafts are i i n same | ‘Then they can be connected by keys ling then this is called alignment of sha! and coupling DMET-30DEMON OF MALI tof shaft a lines isalif” when cents Of Wo shafts are not Spats Then they © be Connected hy ge Hime then this is « figure below shows a Sink 5 jximum tensile stro 16 from 26 my i im diameter rod. Oetarmina thi 1088 developed in the link wn 7049) (ames 9010) (it Ae) wsfite | | i ! } ' i) ! | \ ' + Answer: Given data: F =1KN =1000N d=25mm ad = 4x05) = 490.87 mm? F_ 1000 | 7 a7 Fong 7203 Nim At Section A-A It is observed that point P is subjected to eccentric loading, which causes a direct tensile stress and bending stress, (also tensile at point P). M, = Fx75=75x10°N—mm Y Smm 5 —12.5 = 62.5mm r= 15+12.5=87.5mm Wit Vi _ (1625 +875) ay 47 nm 4 4 = 1% ~fy =715-74.47 = 052mm Y= ty 1 = 7447-625 = 11.97mM ga Mody 0p 210-1197 2 = Fn B= 208 0 7 6.524625 =583 Nim? “@ DMET-31POPULAR PUBLICATIONS centric loading, At section BB © is subjected to eccentri is observed that point " m M, = Fx 100 100x10°N=m r, = 100mm r= 100—12.5 =87.5mm r, =100+12.5 = 112.5mm 9.6mm ty = 100-99.6 = 0.4mm, 1, = 99,6-87.5 = 12.1 mm Mya! 34 100%10" 12.1 18+ F087 0487.5 {tis observed that maximum normal stress will be at point O the value is 72.5 Nimm* (Ans. (i)] o,=0,+ = 72.5 N/mm? =36.25 Nimm? [Ans. (ii)] 4. A hot rolled steel shaft Subjected to bending moment that varies fro, ™ +500), oa tSON-™ and a twisting moment at the critical section varies from sph Clockwise to 100N-m antic! lockwise. Determine the shaft diameter, Where tin Pa, st is 660 MPa yield strength is 340MPa, me comreetion factor for variable twisting momen a Faament is 0.9. Size correction factor is 0.86, ection fa te Fatigue stress concentration factor is 1.42, Consider 90% reliability ang Chose thy reliability factor accordingly, BUT 218 Answer: ©, = 280MPa ©, =560MPa Mow =#500Nm MM, = _150Nm Tru = 350N-m Tan =—100N-m ¢, =340MPa Load correction factor Variable twisting momen Yariable bending moment = 0, Size correction factor = 0,85 Surface Correction factor = 0.87 Fatigue stress concentration factor = = dia of the shaft in mm, First of all, let us find the equi lean / average bending m: 1.42 consider 90% teliability. ivalent t normal stress due to bending joment DMET-32VA A MANOS Bk ue Ma HOC tony V75 210" yn jie bending MeMeEnt a Mam Mw HOH 80 2 3 Varia 25-40 Nin " section modultts, yy DOOKIE mn! 0.0982 nen Mean bending sttess, Ma VISIO! 1782.1 10! my Q.00RDd" Nana! and variable bending stress, M, 325*10" 3309.6 710" a,e— , *s 0,0982d" a Nim equivalent normal stress due 10 bending 4X0, Xk y 6, in as Kae XK Ki dl! 3309.6% 10" x 340x142 1782.1710! _ 10356506 9, GP x280*0.87%0.85%09' d 7 ds Mean twisting moment Pau t 00 , =~ ~=125%10' Nm 2 Variable twisting moment ae 1, = Faas = Ean 350-1100 995,,10'N 2 2 167, 636619.772 uae 36619.77 Nn? 167, 114591559 tr pepe jivalent shear stress due to twisting ca AK 50,6280 = 168N/mm? + 1 Keay Koy Bue - §36619.772 , 114591 5.59 %1T0x142__ 4347621.728 Nim? d d? «168 «0.87 «0.85 * 0.6 d Now maximum equivalent shear stress = lon) Hla) DMET-33aa popurar PUBL 1ATtons gy4762) 728 i j 1! [ y03s680) pay { sey ad ord] [1 sre df [82804478 ia! 188 a od sar 34m [35] 340) DMer34HMI CR AAC HIE RMA MODULE 4 Holo type 1 ty a ateaith MUTI, The platan red be uMnally frnirinntadl ty the eryam Newel by (WALT 200, 2042, 2014) 1) Hotvaraat faint A) Gottar joint Maley Anaen GL) 2 The parallel filet welded joint te dewignad tor (WALT 2040, 2011, 2016, 2017) 4) tensile atrength h) bonding atrongth ©) oompremelve strength ) ahoar atrongth Anawer! Gl) 4 In tranamileaion of compressive load from one rad to another in # cotter joint takow place (waurt 2010) 4) direotly b) via cotter 6) via cotter pin 4) via collar Answer! (b) 4 Awelded joint le hown In figura 4 [waurT 2011) Pe q) Vig: | It the wold at B has thicker fillets than at A, the load carrying capacity, P of the joint will a) incre c) remain unaffected b) b) decrowse d) bo doubled 5. In welded Joint the throat of wold as compared to slzo of wold is [WBUT 2012, 2013, 2016) b) About 0.7 times ) About 0.26 times a) About ¢) About 0.5 ti Answer: (by) JSPOPULAR PUBLICATIONS Way. 1 joint is used to transmit b) axial comprece ae sania ile toad only ) T 2 Ve Io, Og d) axial tensile of Compr! Oniy 2, bined axial and twisting loads mi ©) combin . Answer: (c) f a steam engine is usually connected to the “roy he ston rod of a i 7 fn ars ” ° b) cotter joint ; Bur} 4) bolted joint ‘ 4) universal joint €) knuckle joint Answer: (b) 8. The pin in a knuckle joint is subjected to. 4) single shear and crushing We b) double shear ang Crushing” 2, 4) double shear only ©) single shear only Answer: (b) it lel fillet weld of length 1 ang I 8. A double fillet welded joint with Parallel fi fetes eos Subjected to a tensile force P. Assuming uniform stress distribution the Shey stress in the weld is given by Oweur 2 2p P gz a 22 er Opa V2si sl Answer: (c) 10. A cotter is used to transmit [eur 2017 a) axial tensile load only b) axial compressive load ont ©) combined axial and ‘wisting loads gy axial tensile or SOMPrESSive loads Answer: (d) 14. If the tearing Sfficiency of a riveted joint 1%, i i wa i pia ftlen Teint is 50%, then ratio of diameter ot ft 8) 0.20 6) 0.30 : hemes © ) °c) 0.50 d) 0.60 12, Taper usualh ro) ating aye pulsed on cotter '8 between the (WUT 2013) Answer: (c) 1 in 24 9) 1 in 49 ®) 1 in 50 'd Slot ig Provided BUT 2019] ®) on one 7 Ne Side Only 4) may be Provided anywhere DMET.36DESIGN OF MACHINE ELEMENTS estions , = 60MPa = 60 Nimm* 1 =30MPa =30N/mm? OMPa = 20 N/mm? Diameter of the pin = d 2 b=1Sd a= VA [As per standard] Maximum bending moment 90x10 Sxb 2 2 4 Section modulus z = Maximum bending stress 75710" a ? 32,1 2 SN Sd xe % fi 4 ad hyrd DMET-37POPULAR PUBLICATIONS WhO 16909 10mm [Ane] ular ore 2A shalt of rectangul welde a8 shown in Fig, below. on shear atroas in the wold Ie limiter Answer: Given data 25KN = 2549! Tom = 75 Nim? 1=100 mm 5=150 mm 500 mm 876 Of the weld and 1 throat thick Shown in figure, Area for rectan z mmDESIGN OF NV ‘OF MACHINE ELEMENTS ye know that maximum shear stress ( Tovey) i, 78 Vio) 4p) (“Sy (22) x : Wl | + 2) _ 399.2 S = 399.2/75 532mm ‘ s) os rectangular c i terial ie TOSs-section as is loaded Srermine the dimensions eaincrean FG200 and the tacor. of ately eas ‘oss-section of the bra ng icket_ consi of failure. Assume depth is twice the wat [WBUT 2019] Answer? ‘The stress is maximum at point A in section XX. sees ‘The point is subjected to combined bending components horizontal Y Boe 4 b=2t t+ x Since bending moment is maximum at A, and direct tensile stresses. The force F is resolved into two component p, and vertical component p, F, = F c0s30° = 5000¢0s 30° = 4330.13N Fssin 30° = 5000sin 30° = 2500N ‘The bending moment at section XX is given by M, =F, x150+F, x300 = 4330,13x150 + 2500300 =1399.52x10*N-mm DMET-39POPULAR PUBLICATIONS = ; s! tion XX. Ir js The vertical component F reduces shear stress at see 5 howevey . Neglected. The resultant tensile stress c_., at point A is given by a, 2099.28 «10° nm =O, +0, = The maximum permissible Cm == 8 “o, =200MPa “FOS 35 - = 57.14 Hence, 2092810 | 216507 eri 5 a >" 37.89 (-36739.24) =9 31=33.62=35mm dimensions of the cros section are sean tensile stress is given by 200N/mm* for cast-iron Fg aDESIGN OF MACLINE ELEMENTS ewer cen data: GN p= 2S KN = 25X10°N p=$5.Némm? yoomm, /= 100mm — Lets s0mm 100450 = 150 mm. ize of the weld throat of the weld polar moment of inertia of the throat area of the weld system about G ore 1) om = |-oaontees2et0y _100°(160 + 100)* | 12 160 +2100 0,7075[3888000 -1877777.78] = 1.42110! mm* 7 pistance of load from G Eecentticity ¢ = 100+50=150 mm 7, = 4B=SOmm -GB=80 1, = (GB) +(AB)* = (50) + (80)? =94.34 mm. 550 cos @=—b =$——_— 7, ak 9 =58° Throat area of the weld A=2« 0.707Sxb + 0.707S x I = 0.707S (2«160+100) = 296.94 § mm? Primary shear stress 7 oP = 25x10 _ 8419 Nn? ‘A 296.945 5 Shear stress due to the tuming moment 7, -Pxexr® _ 25x10) x150x94.34 _ 249.1 1421x105 Ss Resultant shear stress ‘Nimm? ra(1) +(t,)° +22, x7, xcosO 2 a ae on, 55x, f( 84:19), (249-1 «(82 } (284 se ES Ss s Ss s S or, S = 28.75mm. “150.7078 = 20.33mm. [Ans.] DMET-41POPULAR PUBLICATIONS dort to a flat plate a8 Bhown inf, a wo A FR on diameter wot anal ie walle eid whoar stron in elee at the wold Le 20 riven, Mind the nian ni iO Anewer ‘ivory dati Desa Se POO KN © 20810'N © 100mm Vet > throat thickness ¢ The Joint is subjee fad to direet shear stress and bending, stress. We know that the Uhtogy area for a circular fillet weld 115 1D OD078 x ADH O10 20x 0875 = 393 1 66m >» 20610" Shear stress, p= = 208 1 131.60 \ x Nenaling moment, MP se = 20810'300 = 6» 10° Nan Hom standard value we find that for a circular section, section modulus nad) nx VxD? ax sy 7 AAD! AX OTOISXD? — 0.107%20% (75) _ 60468 6 mm 4 4 4 Bending stress M 6x10" °, 96. N/mm? = 96MPa. 2 624686 Maximum normal stres: 14 Ca) @, (max) = 5 04 4 ilo) 4° 5296 4 (6) Maximum shear stress ‘N/mm? = OMPa. +4x6=96.4MPa [Ans. (i)] | Vlog ae a8 MPa [Ans, fo the class head. o , the maximum 80 Nimm? and crusting stress = 120 [WBUT 2011] DMET-42GN OF MACHINE ELEMENT yoo N/mm Nim 120Nimm diameter of piston rod at cotter ness of cotter Thi 5 , may taker as oma Considering the failure of piston rod in tension at cotter d,) ~4; xe 1) -0.3(d )x [Ans. (i)] ; 03x27=8.1mm — [Ans. (i)] Let, b= width of the cotter Considering the failure of cotter in shear The carter is in double shear pe2bxtxz or, 35x10° =2xbx8.1x80 227.006 = 28 mm [Ans. (ii)] ameter of socket the failure of socket in tension at cotter Let, 4; Considering 7-{Biay (aF He-a}e or, 35x10? -lelay -(21' |-(4,-28 spo or, ss0=7(d,) —572.55-8.1d, + 218.7 or, Ma J? -8.1d, - 703.85 =0 4, =35.53= 36mm Checking the induced crushing stress in the socket: P=(4,-d )xrxo, €0835x10? = (36-27) x8.1xo,, °.0, =480.1 Nim? DMET-43POPULAR PUBLICATIONS I is higher than o, : We have to determine the value of d, by taking @, = 120. N/mm P=(d,-d,)xtxo, or, 35x10" =(d, ~ 27) 8.1120 d, = 63.008 = 64mm [Ans. (iv)] 4. A 50mm diameter solid shaft is welded to a flat plate as shown in size of the weld is 15mm, find the maximum and oneal biel stress inthe 8 a Buy 200 mm Ge |-iske Answer: Given data: D=S0mm S=15Smm = 1000N e= 200mm Let, t= throat thickness = 0.7075 The joint is subjected to direct shear stress and the bending stress. Throat area of the fillet weld A=1x 2x D=0.1075x 1x50 = 0.707 x15x 2x 50= 166mm! P_ 10000 A 1666 ~. Direct shear stress, 7 = = 6N/mm? = 6MPa Bending moment, M = P xe =10000x200=2x16* N-mm From standard value, we find for a circular section, 2 2 2 Section Modulus z=44P _ #%0707x$*D* _#0.707%15%(50)" _sogye,, 4 i M _2x10° + Bending stress, , =f .2*10" gov 7” 20925 ~ 26 N/mm? = 96MPa Maximum normal stress 1 } Funny 3% #504) 44 P91 96) cae = 48+ 48.4 =96.4MPa [Ans. (i)] > aana DESIGN OF MACHINE HLEMBNIo Lad +40 = 3 one 1 (06) +46 ig MPa Ans. Gi} yired to design a k ign a knuckle joint as shown in Figure below. The axial force 5, [tis eon the rod is 15KN. ie 9 2 ose el | The fork, ayb and the pin is made of plain carton steo! ngth of 400 MPa. The compressive yield strength is te that in tension. Shearing yield stress is 0.677. Using a factor of safety b, a and D1 as show in the figure. (wet 2017} sa ofS “and 4, ‘Answer? Given data F=I15kKN=15x10°N Oy = = 400 N/mm? Oy = Oy = 400 N/mm? 577 oy = 0.577% 400 = 2308 N/mm? a = AE =80 Nine? 409 _ 39 Nimm? 5 2308 _ 46,16N/mm? t= Let, d = Diameter of the rod Load transmitted pa2xd’xo, 4 on 15x10’ = 4d? x80 DMET-45ONS POPULAR PUBLIC A110 28 unm (Ans: Cl 18S et (lO speaimensions are a8 Now, the varie Prameter of kone le pil : i d- tomm ) eter of eye, dd dx 16 32mm Outer ia collar e pin head and ¢ Diameter of er ri ae ale ey od end Thickness of singers a Pe en 0.75d = 0,75x16 12mm 0,5x16= 8mm Ie shear therefore load Thickness of fork, Thickness of pin head, f= 0.5d =0 Now, since the knuckle pin is in doubl P atta) or. 18810 = 2 Fx(16)r 1=373 Nimm? The single eye or rod end may fallin tension due to the load, the load (P) 15x10 = (d, -d,)ixo, = (32-16)x20xo, 9, = 46.87 Nimm? The single eye on rod end may fall in shedrin 15x10" =(d,-d)xtxr 7=46.87Nimm? For crushing the rod may fall P=d,xIxo, 08, 15x10? = 16x 20xo o,=4 : g due to the load, the load (P) 6k.87 N/mm? o, = 46.87 N/mm? may fail in tension due to the load = (4, ~€)24, x6, =G2-16)x2x % = 39.06 Nimm? ay fallin cru Wg shin or, 15x19? xo, 8 due to the loag +1621 g % =39.06 Nim? DMET.46DESIGN OF MACHINE ELEMENTS iris required to design a knuy . 6.9) (yoting On the rod is 15 KN, THe ht’ Joint as ah oe aC N. The fort Shown in figure below. The axial treet 3008 eae tensile yield strength at span the pin are ma ia eartcs nis the same as thy Imm*. The c sonal Sf at in tension. Shearing yield strose ‘ gactor of safety 5 for all type of load. ‘Stross is 0.5775. Use a ») What do you mean by SURGING of spring and how can it be eliminated? UT 201 ; | | oR, (wel a What is surge in spring? TEES) Answer: ° a) Refer to Question No. 5 of Long Answer Type Questions. b) When one end of a helical spring is resting on a rigid support and the other end is loaded suddenly then all the coils of the spring will not suddenly deflect equally. In the lessoning the end coils of the spring in contact with the applied load takes up whole of the deflection and then it transmits a large part of its deflection to the adjacent coils. This results in very large deflections of the coils and corresponding very high stresses. Under these conditions, it is just possible that the spring may fall. This phenomenon is called surge. This surge may be eliminated by using the following methods: i) By using springs of high natural frequency. . ii) By using friction dampers on the centre calls so that the wave propagation dies out iii) By using springs having pitch of the coils near the ends different then at the centre to have different natural frequencies. 7. Design a Spigot-Socket-Cotter joint and find the major dimensions like d, dy, do, 4s, dy, a, b, t, e and f as shown in the figure 1. The cotter joint is to carry an axial tensile load F = 40kN, applied statically. Material used for all the components is plain carbon steel for which the following design stresses may be used 0, =50 en Nimm?, o, =90 Nimm?, r=35 Nimm?. Assume: Thickness of cotter to be %" times the diameter of spigot at cotter position. (WBUT 2014} DMET-47POPULAR PUBLICATIONS Clearance Spigot ABR Gn Hike ay wee it ae aa Socket collar TR) ” _ Taper 1m 30 Fig: 1 Answer: Give data: : F = 40KN 40%10'N; ¢, = 50N/mm?; 90.N/mmi 1 7=35Nimm?; 44 Let, d= diameter of the rods Considerin, 8 the failure of the Tod in tension 40710" Wr 10, =f cd 50 4=319%32mm (Ans, @) ng the failure of the spi 10 La) a nt) 4, =38.6% 39 mm ot 8595 am a7 Checking the crush 40710) = g Consider igot in tension Across the weakest section 6, -[2a Yea, ~4)s0 =26.8(4,)? ing stress I Xtxo, 3949.5 x6. 105 Némm? So, the Values of g So, we have to coy 40x10) d, oF, 40210? a, 1 4nd tare not safe nsider Ika, crushing Phenomena M0210 = x4 op 42.16. 44 sym Ans, (i DMET.4gDESIGN OF MACHINE ELEMENTS 44 4 Considering the fhilure of the socket in tension ae ; 1mm (Ans. (iy TOs the slot [x 40v10" =| {ay <(d,y} -¢a. d x I wlo, | 74d,» aay} ca, aan |s0 40*10' =| 404s -1820.8-11 4, «484 |50 +1000 axl 0.784.) —11d,~1036.5 5 0.78d,)° - 11d, ~1836.5=0 d, = 56.08% 58mm [Ans. (iv)] Considering the failure of the cotter in shear 40x10" = 2bx tx 7 = bx 11x35 b=51.94=52mm_ [Ans. (v)| Considering the failure of socket collar and cotter in crushing 40x10! =(d, ~d,)xt xo, =(d,~44)x11x90 d, = 84.4 = 85mm [Ans. (vi)] Considering the failure of the socket and in shearing 40 «10° = 3(d, —d, Jexr =2(85-44)ex35 e=13.93=14mm — [Ans. (vii)] Considering the failure of the rod and in shear 40x10 =2axd xr =2ax 44x35 a=12.98=13mm —_[Ans. (viii)] Considering the failure of spigot collar in crushing aonid =4[d) -, Jo, =4[(a,y -(44) Jo0 d, = 50.01% 51mm [Ans. (ix)] Considering the failure of spigot collar in shearing 40x10 =a dx fxr =1x44x f x35 f =8.26=9 mm [Ans. (x)] 8. Design the spigot and cotter joint shown in Figure. To support 28 KN in tension and 28 kN in compression. The material for all components for the joint is steel with the allowable stresses in tension, compression and shear as 50 Nimm’, 60 Nimm? and 35 Nimm? respectively. Calculate the values of i) diameter of rod, d li) diameter of spigot, d, DMET-49POPULAR PUBLICATIONS iii) thickness of cotter, / iv) width of the cotter, > v) length of the cotter, / vi) diameter of the socket, (, Answer: Given data: P=28KN =28x10°N og, =50 MPa =50 N/mm? o, =60 MPa =60N/mm 5 MPa, =35 N/mm? Let d = diameter of the cotter Considering the failure of the rod in tension. P=4/ xd" xo, or, 28x10? =F xd? x50 d = 26.7 = 27 mm[Ans. (i)] Let, d, = Diameter of spigot £= Thickness of the cotter Considering the failure of the spigot in tension across the weakest section Pal Fada, or, 2810? [Bay = dx |» =26.8(d, Jd ,=3232=33mm je Thickness of the cotter ¢ = 4 — =8.25mm 418 Now, considering crusting P or 28410? = 33%8.25 x0, DMET-50DESIGN OF MACHINE ELEMENTS 7 1028 > 0, = 60.N/ mm inensions a HOt sae aexi0? =d x22 60 4 4 3.2. 44mm — [Ans (ii) [Ans. (ii)] arb = width ofthe cotter tSnsiering the failure ofthe cote is shear Since the cotter is double shear, - pe 2bxixt or, 28x10" = 2b «11x35 b= 36.36 [Ans. (iv)] Length of the cotter = 4d =4%27=108mm (Ans. (v)] Let, d, = diameter of the cottar. Considering the failure of the spigot in crushing md 2g yt pala) Jo, or, 28x10" =4{(d,)* -(44)*] 60 d,=61.6662mm — [Ans. (¥)] 4, 2) Two rods are connected by means of a cotter joint. The inside diameter of the socket and the outside diameter of the socket collar are 50 mm and 100 mm respectively. The rods are subjected to a tensile force of 50 KN. The cotter is made of steel 30C8 (5,, = 400 Nimm’) and the factor of safety is 4, the width of the cotter is 5 times of thickness. Calculate: i) width and thickness of the cotter on the basis of shear failure; and ii) width and thickness of the cotter on the basis of bending failure. b) Derive the equation for the length of flat belt for a cross belt drive. [WBUT 2016] Answer: a) Given data d,=50mm; d, =100mm ; P =50KW =S0x10°N; S,, = 400N/mm* For steel Weknow, r, = 0.85, = 0.8400 = 80 Nimm* 1, B20 Nii’ Now P=2brr DMET-51POPULAR PUBLICATIONS on, $010! = 2x Str 20 or, $0%10' = 107 » 20 r= 250 1158.18 wane, [Ans. (i)] b= St= $x 16= 80mm 0, = O09 N/mm? 4 oO. +0, 91, 400 = 1004 0, ©, = 300 Nim? Let, 4, = Diameter of socket collar d= Diameter of the rods For Steel, 2d 4 =4133=42 mm 4.=2.4d =100.8=1011 mm 2 BG or, 300 = Pld, +0.5d,) xB 50%10°(10140.5x50) ? or, 300 = ) _ 25x10? x 126 20% SP 35 20 20-4=21mm tans, b-Se2ict0som Gi) b) Ler, Wand r= t DMET.s)DESIGN OF MACHINE ELEMENTS rom Geomelty, O, LOF a (rad) EF + Are FKH+HG =2(Are JE+FE+MC FK) OM _O\E+FM _ nt sin G0, 00, as as ar is very small sing=a 42% 6 Jan Are Jip (E+) K=n [44a =AlZ 7 EF = MO, =\(0,0,) ~(0.M) =F = +n = 1-4) x ero yee) + jee 2 x 2x 2 L=2 “(Sea e Ce +h =4a 2 2x 2 : 26 +n) +a, sje sel | (nth) = a(n +13) +2a(r +) + 2x— nth x nth L=n(r,+n)+2x (itn) (nn) +2x- (+r) 424+ DMET-S53pOPULAR PUBLICATIONS that two mite ateel rod 0 lal toad of a mw oe matorial® 9 aro to bo connected by a ign the joint completely, 10H tenet an working atrowe for both (he Inehear and 160 Nimm’ in oru nat very long Alea draw the # ushin ketch of your joint. Anewer SKN 80N inom aX Nin Joo Nin 1) Failure of the solid rod in tension: Vel ds dia ofthe nid s/4nd’ va, SISON10" © #/4x ASR sd sOmm Diameter of knuckle pin, d, = 50mm = Outer dia. of the eye, d,=2xd=100mm aoe of knuckle pin head and collar, d, =1.5d = 75 mm hickness of the sin = "wavs cP 3tSmn ng TNickness of pin head, t, = 0.5sed=25 mm. = wre of the knuckle pin in shear: AXA) xr 218010" 215010) >, <47.62N im? Or im 0 Failure o thesia SOs) (4 le eye end j 2150.10! r or 80 Nimm? in tor Hesume that {ho rods aro to jy mn)DESIGN OF MACHINE ELEMENT 50x 6360 550% 10" 47.62 MPa © 90. N/mm y gaiture of the double eye end in tension: sox to" =(4. d,)* 21, xo, | 15010" = (100-50) 2% 38x60, @ = 30.48N mm? 5 <80N/mm =) Failure of the double eye end in shear: 150%10" = (4; -,) x24 x8 5 15010" =(100 - 50) x 2x 38x 7 9.47 N/mm? <68N/mm 5) Failure of the double eye end in crushing: 150x10° = 4, x24 xo, = 15010 = 50x2%38x0, =39.47 N/mm? 20. g, <160 N/mm? Design of the knuckle joint is safe. | steel column by means of five standard bolts 2s 41. A bracket is fixed to a vertical sses of 70 MPa in tension and 50 MPa shown in the fig. Assume safe working stres in shear. Determine ' i) Diameter of the fixing bolts and ii) Thickness of the arm of the bracket. [WBUT 2018] 100 —_ 100 o || + Je—20 a All dimensions in mm Answer: Horizontal component of 45 KN W,, = 45sin 60° = 38971 N Vertical component of 45 KN DMET-5SPOPULAR PUBLICATIONS aan Wy 38971 994 25n) Direct tensile load on each bolt, W, = 3 5 oer eae eons N-mm (anticlockwise), WH, «25= a 2500 As00n, 5 5 Turing moment due to HW, about edge of the bracket 7, =W,x175_ = 22500%175N-mm (clockwise) -mm (clockwise) Net unig momen ISN = 2963225 N ... (i) Total moment of the load on the bolts at the tilting edge W,(L) +2, (L,)? = 2W, x50? + 2W, «150? = 50,000H7, N-mm ... (2) From the equation nos. (1) and (2), by equating these two 2963225 N = 50000 wNevy ‘x tensile load on e: Direct shear load on each bolt = W”, = ach of upper bolt, Wt, = WL, = 592.645 «159 = 88896.75 N Tensile load On each of the Upper bolt, Wt Wt+ Wt, = 7794.20 +88896,7: =96690.95V Equivalent tensile load M5 da) : $(0650 95 +97108.91) =96899,03 Tensile load on each bot = : (4. xo, = 7854 x(d_)? 79 4. = 47.98 4.=41.98 mm from coarse Series : the ‘standard core di ST eesPonding size of bol; i = A= br = 9g 2 Fal is MSé i 49.0177 min kness ofthe arm Of the bracket CUS area of 1hwet tonsil qi na EN = 70t = 46.36mm 42. A bracket is Subjected to a force of P = vertical as shown in Fig. The bracket is taste i i taty fel 2 raced ot Plain Carbon steel 30C8 (Syt = 400 Nimm’) and stress theory and determine the size of bolte stress. Assume maou ora N, inclined at an angle of 600 with the ned by means of for identical bolts to Answer: Given data, p=SKN S,, =400N/m? FOS =5 Permissible shear stress Sy S, _ 0.5x400 Tew = Pg = FOS FOS 5 The force P resolved into horizontal and vertical components. These are — P, = Psin 60° = $000sin 60° = 4330.12N P. = Pcos60° = 5000cos 60° = 2500N 40N/mm* Effect of P, The horizontal component P, is parallel to the axis of effects: i) a direct tensile force on each bolt the bolts, It has following two DMET-57A olts (G) in clockwise TIONS four bolts (G) i is Site pysule \R i poruL Oy (ld) i istance ‘ four bolts is at a distance (60%, ntre of gravity © fthe force P, is ata distan.)” ic e, the cet in the figure. ! © of lication of is (200-14 : jower edge. The point ne of the force P, is ( 0) op os ec . 1c. Therefore, © ( ‘M,) due to horizontal Compo, (No.0 » the lower edg meee i f gravity. The tuning me entre of y ahout the enh 5.2 Nemm erent 40 = 4330.13 x 40 = 173205. Mu =Bx 33 in the clockwise direction. acts int Me . (ii) : wit wo effects — ® on i Its. It lies follo’ ‘ing two the axis of the bolts. P is perpendicular to “ ot i ise direction. “Sune moment abot the tng edge Cin he clock ‘The direct shear force on each bolt is given by — p= Fh __2500 easy i) * (No. of bolts) 4 ‘The distance of the vertical component P, from the tilting edge C is 240 mm. The tuning moment (IM, ) due to the vertical component is given by, M, = P.x240= 2500x240 = 60000 N-mm 4, acts in the clockwise direction, . It can be seen that tuning moments due to horizontal and vertical .. (iv) components are Clockwise and the resultant tuning moment is obtained by their addition. The resisting forces set up in bolts loa » af proportional to their distances from the mat “ ae bolts, ae I, are at the farthest distance four the edge ¢. z ne force due to the t i e maximum for wo dened iy fendency of the bracket to tilt about the edge Cis rete ea) 27 AF +2) (173205.2+ 6009), ——— 260 20260 6°) =1S11.75y the tensile force aor, : acting on each PRs pr 'ch Of the t se Tete gg 253s 1 75240436 yr N° POMS, denoted by | iver bolt is Biven F + (vi) y From (i) ang (v, + (vy) DMET-sgp’ 2494.2 _! 8 a | suis the shear stress in the bolt prom P 625 : P25 Nimm A mm stress in bolts syaximum shea |( 2494.28) (625) _ 139499. \ A —_ 24) A From standard table, the standard size of the bolts is M, (4=366 [Ans.} 43. Design @ cotter assuming suitable data that is required. (WBUT 2019] answer: ; Design of socket and spigot cotter jo Clearance Couer (Qt03 mm) ses et cola Socket ——_J P P | { P=tensile force acting on rods (N) Spigot d= diameter of each rod (mm) d, = outside diameter of socket (mm) d; = diameter of spigot or inside diameter of socket (mm) diameter of spigot-collar (mm) d,= diameter of socket-collar (mm) P=tensile force acting on rods (N) d= diameter of each rod (mm) 4d, = outside diameter of socket (mm) 4,= diameter of spigot or inside diameter of socket (mm) 4; = diameter of spigot-collar (mm) d, = diameter of socket-collar (mm) 1, = Permissible tensile stress for the rods material, DMET-59—_—_ i yOu IOATtONS aul i POPULAR rial ior al conten ale! for thee ay sires teas far the ¢ pigsite She Permiesite ceshink ® ys are tne jected 4 avi 10" ; angration ie © Jot de ee! ening oF the eatter me “" int and find out the dimension Failiiten iy anaideree Nh, faite, one strc equatl rious dimension’ ‘of the cotter joint Mod ty “ég =. Lot - Spi 2 ti Joctod slocted Following The mvs are sh fot of stress CONE co initial Light coter jo! naile (Fee ie «Theft a The stresses de t fe Inonder to design the parts ann at iterent € Based on each (ype 0 used to determine the vat pw A on is wellten and these qi alee ofthe rds ena “= of di ‘ a diameter dis subjected to a tensile force P. Fail Z 4 The We esti in ten section of sion across the we the spigot is tha eakest section (or slot); Section which has a slot in it for thi r lot in | ¢ cote D ) rea under x RETh tension Dh Resin C x ae 18 Area Xa ; S=H Section at xx TY dsay [8 « DMET«,DESIGN OF MACHINE ELEMENT ma of Lee ; ' : ' at - Seton at XK ! \ : ~4- 1 ' ‘Area under: - i - , ' tension SO oh, Pp Sze Ed.) dent (Flay -d, xtle where, thickness of cotter ¢ =0.31d From this equation, the diameter of spigot or inside diameter of socket (d2) may be determined. Tensile Failure of the Socket Across the Slot: ¥ cute (a)POPULAR PUBLICATIONS Resisting Area l(a) (a) | (4 ait _ P (a) | (dt)! Tensile strength. 0, = = all’ {tay ay] are aay be determined, From this equation, outside diameter of socket (d1) may be det ed P- Shear Failure of Cotter: Shear areg — > —., he +, p——| Pa —I P From this equa ba where, spain ith oot 22 : , sible shear stress i ie determine, fl ‘Otter mate rial DMry ..DESIGN OF MACHINE ELEMENTS pear Failure of Spigot End: Ls IG” spigot end is in double shear ‘The area of each of the two planes that resist shear failure is P where, 7 = Permissible shear stress for the Spigot material From this equation, the distance from the end of the slot to the end of the Spigot (2) may be obtained. Shear Failure of Socket End: ‘Area under P Socket end is in double shear fa oo 2(d,-d,)e P=2(d,-d,Jexr where, d, =2.4d From this equation, Distance (c) may be obiained. DMET-63POPULAR PUBLICATIONS Crushing Failure of Spigot End: A gee} Thatebe= () i tress ON a Narrow r¢ causes compressive S| Setangut, As shown in Fig, the force P tt thickness ¢ and width d, a p 9, td, Crushing Failure of Socket End or Socket Collar: dy P p to C= BY] ¢ =| + Area under al crushing © a (4,-d,)r From this Eq. diameter dj can be obtained. Failure of Cotter in Bending:Vitara HANAN OP MACUL LAMBS “(4 ly op y (HO) | 4 Awall bracket With rectan \ Fig. The material in ‘gular ore mine the din {wauT 2019) 280 t PASKN Answer: The stress to maximum at point A in section YY since lending moment is maximum at A. The point is subjected to combined lending and direct tensile stress. The force F is resolved into two components.ICATIONS POPULAR PUBL . 13N pr, ~ Feos 30 5000cos 30 ae : 000sin 30° 2500. IK Fcos30" re is The lending moment at section YY is 8! My, Fyx1254 250 4330.13%1 25+ 2500 x 2: 1166.26x10°N-m e . uy (I 166.26%10")x# 179.410" jon o,=—2= u : or Lix(2e | ri (2) | , ‘The direct tensile stress due to component is Bier y of 433013 2165, 06 smn? 4 aa . 4 2 tion YY. It is however sma} ang The vertical component FF, induces shear stress at sec neglected. . The resultant tensile stress o,, at point A is given by _1749.4x10" | 2165.06 2 Frag = FOS 35 1749.4x10? 2165.06 tad Now, Hence, 3061 7 20 ~30616+37.97 =0 a Ghali 35 [By hit and trial) fe cross section are 35970 mm The di o, 200 > = [o, =200MPa=200 Nim? for cast-iron FG 209] [Ans]DESIG: MODULE 5 OF MACHINE ELEMENTS Roles Type g pstior “onest value of riveted joint offic — 1 Lemgingle riveted butt joint NCY is assumed in c: fy double riveted butt joint b) single tiveted ta _— ae east, pasted has a head on one end and (WBUT 2010, 2017 has head at one end @ nut fitted to th ») fo be joined and other end fits Into tapped hole in the oth e other part has both ends threaded @)_has pointed threa (©) Answer j.aTur Buckle has ,) RH thread at both ends b) LH thread at both ends c) LH Thread at one end and R.H ¢} thread at the middle section cen (WBUT 2011, 2012, 2013, 2019] Answer: (C) it is tight a When a nut is tightened by placing a washer below oil, the bolt will be subjected a) tension b) compression ¢) shear Py pe ‘Answer: (4) 5, The included angle in Acme thread is [WBUT 2014] a) 60° b) 55° ©) 47.8° anes Answer: (4) 6. The ratio of diameter to pitch of a rivet is computed from (WBUT 2014) a) shear efficiency b) tearing efficiency c) crushing efficiency d) load capacity Answer: (b) 7. Ifthe tearing efficiency of a riveted joint is 75%, then the ratio of diameter of rivet to the pitch is equal to [WBUT 2012, 2014, 2019) a) 0.25 b) 0.50 c) 0.60 a) 0.75 Answer: (a) 8. The centre to centre distance between two consecutive rivets in a row, is called (WBUT 2014) a) margin b) pitch c) back pitch d) diagonal pitch Answer: (c) DMET-67POPULAR PUBLICATIONS make the joint ENBUT 2014 % b) stronger in tension —' 2414 , 8) free from corrosion 4d) loak proof ¢) free from stresses Answer: (d) joint is to objective of the caulking ina riveted I 8 The [Way i s Is . ne 10. The included angle in cme thread: ars afin, ; b) a) 60 Answer: (d) 11, The designation M33 * 2 of a bolt ST an &) metric threads of 33 nee ors men? ‘en th cross: 7 d) none of these Answer: (c) Meur 2016 xy, 12. In a flange coupling, the flanges are EO ae by means eu 3 i soot taper bolt d) none of these 2016 Answer: (a) {2 The Permissible stress in a fillet weld is 100 Nimm?. The weld has equal |. length of 15 mm each. The allowable shear load on weldment per cm length of a = WeuT 29,,° a) 22.5 KN b) 15.0 kN c) 10.6 KN 4) 7.5 ky Answer: (c) 14. The pipe joint Mostly used for pipes carrying water at low Pressures is 4) Socket joint - b) union joint (Weut ©) sleeve joint 4) socket and spigot joint “4 Answer: (; c) 16. For plates of thick, i i ied “tes of thc ness greater than 8 mm, the rivet diameter is cae Out by dang Bee T 2017] Answer: (c) a 9) d= 6 9) d= Bui 16. Two shafts & ang that of shen The rat Made of same material. The diameter of Shaft B is twice , Power which can be transmitted by shaft A to shatt Bis . 05 ») 0.25 2018] | Answer: Pyeuy er: (c) ©) 0.125 ) 0.0625 DMET-6gDESIGN OF MACK . a bolt is subjected to sho, ” MACHINE ELEMENTS: whe? 4 in order to Ck loadin 7, Wired in of Prevent breal 9, the rositie fonsiderank By inthe midane ®t re re aa thread ©) ANY Where in the bert? head WUT 2019] nwer © ’ airoraft Body 8 usually fabricated 18 ay welding Precasting ©) riveting (WBUT 2019) ener 4) casting jien bolts are 8 5 elf locking bolts [WBUT 2019} f) gesigned for shock load c) used in iaiorah application rovided with hexagonal depression j 4} Griform strength bolts sion In hand answer: (8) 1.) Explain the methods used to make the riveted joint leak proof. a ae BUT 2009, 201 b) Asingle riveted lap joint is to make of 10mm plates. Find the diameter of vets, their piteh and the efficiency of the joint. Take permissible shear stress is 64 MPa and permissible tensile stress is 80 MPa and so design the joint that its strength to vithstand shear of rivets cqual its strength to withstand tearing of the plate across ne line of rivet holes. [WBUT 2009] answer: ) In order to make the joints leak proof or fluid tight in pressure vessels like steam oilers etc. a process known as caulking is employed. The tool used for this is about 5 um thick and 80° angled. It is blunt and the rivet is made level with it. Caulking tool Fullering tool Cautked diver 1 T\20" TY Lit 1 1 ae \ 1 | ! i Fullering Caulking other process is fullering in which a fullering tool with a thickness at the end. DMET-69POPULAR PUBLICATIONS b) Given data 110mm o, 8OMPa 6) O4MPa Pol , Leta, © 120 MPa, 2. © P= Py Pim (p- dy~a, Pym nnd? xr [?= pitch; d= Diameter of the rived ~ 4 4 Pie dia, a, (P-d)txa> ~xd? yy dk xa, 4 4x10 x120 3.8 = 24mm [Ans. (i)] P.= 24 10 120 = 28800N a= (P~d)x 10x 80 28800 P-24=—=* 800 p=60mm. (Ans. ii] 28800 =e 80.6 6005 i ” BOxt0x80 ° (Ans. (ii 2. Two mild steel tie bars, for a bridge Structure are to be joined b Joint with double straps. The thickness of the tie bar ie 12mm and, ae he, ree 400 ae Design the joint completely taking the allowable stresses = 100N/mm?; f= 75N/mm? and S=150N/mm? ; aoe ‘ (BUT 29; Given data: ¢= 12mm J, =100N/mm? Js =75 N/mm? 4. =150N/mm? . d= From Standard y, Ans. (i diameter 20 mm, sO 1.5 mm and correspoDESIGN OF MACHINE ELEME Number of rivets, b= joad P= (b-d) xt f or, 40010" = (4 Lean Width of the rod Tensile! 5 21.5)x 12100 354.8 © 355mm e joint is a bi (Ans. since. the joint is butt joint with double cover plate therefore the rivets are in double o, the shearing resistance w 0. g Fesistance will be 1.73 times of ring resistance of one rivet a shear xd°xfi< x > d°% f= 1.15 pe CLS) «75 = 4765035 N Crashing resistance of the rivet, P.=dxtx f= 1.5x12x150 =38700 N . FP _ 40010? f the rivets m=—- = = iii Number ofthe rivets m=-p-=—— = 10.3311 (Ans. (iti) Thickness of butt strops 4, =0.75t=0.75x12=9mm [Ans. (iv)} 3. A steam boiler, 1.2 meter in diameter, generates steam at a gauge pressure of 0.7 Nimm’. Assuming the efficiency of riveted joints as 75%, find the thickness of the shell. Given that ultimate tensile stress = 385 MPa and factor of safety = 5. [WBUT 2011, 2014) Answer: Given dat D=1.2m= 1200mm P=0.7 N/mm? = 15% = 0.75 PD OP og 27 29mm 20,xm, 2x 77x0.75 Thickness of the boiler shell t= 4. Two plates of 10 mm thickness each are to be joined by means of a single riveted double strap butt joint. Determine the rivet diameter, rivet pitch, strap thickness and efficiency of the joint. Working stresses in tension and shearing as 80 MPa and 60 MPa respectively. [WBUT 2013] Answer: Similar to Question No. 1 of Short Answer Type Questions. DMET-71ON int. The axial f, knuckle joi force, by means of a ade of plain car trod TNT a ea am e ron .8. The yield stron rt! S,, = 380 Nimm?) and the factor of safety is 2. ‘ath, XY (S, = Calculate ay, 57.7% of the yield strength in tension. ; i) the diameter of the rods and it) the diameter of the pin Answer: POPULAR PUBLICATIONS Sy__ 380 _159 Nim? We know, tensile stress o, = S#. = 380 FOS 25 ; Shear stress ¢ a 152 =87.704Nimm ') Considering tensile failure of rods —* P a/4d? Pe AX25%10 a9 414 aes mxI52 = 4=1447mm = [ISmm "}) Considering shear failure of pin: . oP sdf = SKIP 9 4g mEq” exer a4 >, =13.47 214mm &. For the three bolt system ag shown in Fig. 1. Determine th Tratric system ifthe factors of Safety and shear stre, and 200 MPa respectively, @ size of bolts ngth of bolt t's materials rez MBUT 2043 Answer: Fig. Given data DMET.7yD DESIGN OF MACHINE ELEMENTS 100 MPa ppesign tFe8S Load applied Total shear area load applied 19000 design stress 100x10° design stress also, desig otal shear area = 19x10 ‘m? _ total shear pear area for one bolt (A) =6.33%10'm? 3 Kppond= fit = [ROBO germ 7 a a The minimum metric specification required for the bolt is M10. [Ans.] joint is i he joint is F and iveted joint is shown in Fig. Ifthe tensile force subjected by the an resimam permissible strength in shear of plato materials is S. Find the thickness of the plate, [WBUT 2019] a a we [Ty F : F 1 we | t ro jor Given data, o28 P=F é=d Let, thickness of the plate = ¢ Tearing area per pitch length, DMET-73POPULAR PUBLICATIONS s 3 Long An: are connected by means of a coy, 1 f a roof tr |. Assuming that th, "ling. ramenen ine rmeximum pull nthe rod Wm: BD Nin aa toy Stress in tension compression and Sane How much would be the, respectively. Design and draw 7 together for one turn of the coupler? iston rod to ) Design a cotter joint to connect a p the cross-head, The : Matin, . Assuming that all the parts are steam pressure on the piston rod is 35 tN esible stre may the same material having the following p =90MPa Way , = S0MPa; + = 60MPa and , = T ay Answer: a) Given data: P=30 KN=50x10°N ¢, =70 Nimm? (0. Nimm? o, =80N/mm? , ‘We know that the design load for the threaded section. P,=1.3P = 1.3% 50x 10°=65 x 10° Let, d= diameter of the tie rod 4. = Core diameter of threads on the tie rod Consider the tearing of the threads on the tie rod at their roofs. We know that design load P, = 65x10) Zaye, =F y70= 55(d.)° 5*10'/55 = 1181.8 Standard core d oftierod 8" 834.093 mm and Corresponding nominal diameter of tet 4=39mm ; Cfo lenth of the coupler nu (Ans. (9) Onsideris ing the Shearing of threads at their roofs, in the Coupler nut, DMipr ..DESIGN O1 1GN OF MACHINE ELEMENTS pd De get! © (1d 34.0995 1) 49 one ose 10" 4,093 inlard COUTSe Size We take 20.22 w put for § pede 30m Now, for d= 39m pitch of the threads 4 mm, A" Hl number of threads per mm length i J 02 a YM 025 We know » (0) xnxtxe, 1 1A rag? o1,65410' =| (39)' - 04.093) ]:025:39x0, =27500, g - 65%10"/2750 = 23.6N/mm? since the induced crushing stress in the since th thread permissible stress, therefore the design is safe. hee nae ae Let, D = Outside diameter of the coupler nut. Arial load, P =F(e -d')o, 50x10" ae ~39) 70 50x10 x4 _ 50x10” mT 55 or, D? = 2430.09 D=49.2= 50mm. [Ans. (ii)] Let, D;= Outside diameter of the coupler and D, = Inside diameter of the coupler =d +6 =39+6=45 mm. Arial load, P “uD, -(D)'}6, (D’ -39)= = 909.09 2.5010? = AW, J (45) ]x70 = 55{(D3)° ~ (45)"] or, (D,)? = 2934.09 1D, = 54.16 Since minimum outsider diameter © I.Sd= 1,5%39 = 58,5<60mm, » Dy= 60 mm, f the coupler is taken as [Ans. (iv)] DMET-75DOAWAAS PURLCATIONS [Ans. (v)] [Ans. (vi)] Ans. (vii)] 5 20 ven ae ee THe AN drawn together ie one tum of the coupler = 2 pitch of the thr ead <9 [Ans. (viii)] += Siem =35x10M Diameter of boston rod at cotter: t= Thickness of cotter = 0.34, °S tensioa az comer a, x0.3d, | 50 Pa[ Dud.) 4.1] [Fx(a,y [Ans. ()] idth of cotter ponsigering the shear =2bxtxcr= 2b x11.4x60 or, 35 x 10° 20xbx 114 35x1 “6 =————_ 955 ii) é mais 25.5=26 mm [Ans. (ii) = Diameter of the socket Considering failure of socket intension P= {44a babe “(2 GG? 69] ~(¢, 5)" ~$6705.7— 570d, 9, 39.24(4,)* 5794, — ~ 7045.7 =9 4, = 510+, eee ay p ) ~38)x11.4) x50 +21660 0r, 35x10? =39 9, 4d, = 93.002 = 93mm. DMET-76pecking the crushing streg vow y (93 -3Rx1 ang — = SS.8MPa 62 sjow then permissible < bele crushing g ign is safe tress 1 a bracket iS riveted to @ column a stress UMN by si petow. Shear im the rivet is limited ta mea ous! ze a8 shown in Fig. '4. Determine the diameter of the cows (WBUT 2010, 2015] rivet. I i [All dimensions are in mm] Answer: DMET-77POPULAR PUBLICATIONS Given data: n=6 P= 60 KN = 60x10'N e=150mm t=1SMPa =15N/mm? i refore the centri Since the rivets are equal size and placed symmetrical, the e of ravi, " yw that direct shear | the rivet system lies at G as shown in Figure. We kno’ oad on rivet, =10000N ” rivets 1, 2, Let, FoF Fo, and F, be the secondary seat lad on Ie vets 1,2, 3,4, 5 ana distances /,.1.,l,.l,,l, and 1, from the centre of gravity (G) at the rivet system, From the figure (700) +(75)° =125mm hah =75mm we Now, comparing the tuming moment due to eccentricity of the load to the Tesistin, ‘moments of the rivets, we have - Pea Flay' ey ey dy day 0] 44 [aay +2 60x10" 6 and I, fA 2 2 6010? «200 = [4 (125)" + 2«(75)"] F =35294.1.N Since the secondary shear loads are proportional to the radial distances from the centre gravity. a Therefore, L 15 Fy=Fx2=35294.1x2 - piatiias 35294.1x 21176.4N- sin yr tare ea "78 cond = 6B, = Se OG ne shar load on rivets Fand 4 RVR RY PH cos, DESIGN OF MACHINE ELEMENT the direct and secondary shear loads on each rivet, we see that the rivets, 1,2 y loaded. From the geometry of the figure: " e100)" 5204.1) 4210000» 15294.140.6 42061.9N resultant shear fond on rivet 2, RPK, 100004 211764 IT6AN sec that the um resultant shear load is rivets | and 3, if d is the diameter of Jen maximum resultant shear load (R, or KR) and We rivet hole, 42061.92 xd? xr xd? x15 4 4 d? = 3570.3 d= 59.11=60 mm according t Indian Standard, the diameter of he rivet hole (4) is 50 and corresponding ‘diameter of rivet 48 mm. ize, as shown in figure. 5. a bracket is subjected by moans of 4 rivets of samo Determine the diameter the rivet if the maximum shear stress is 140MPa. [WBUT 2014] 20KN fe 30 30 30 All dimensions in mm Answer: Given: 1=140MPa= 140 N/mm? Let, d= diameter of the rivets Direct shear load on edch rivet, P_ 20x10 Rows A =5000N Centre of gravity “G? will be at 45mm from format rivet DMET-79ROPULAR PUBLICATIONS Hyun the gute [let Be Be are secondary shear load o, are the distances from the rivet, toy fe he ¢ & ‘Sim su re Br, ism ‘ ay ar eay 151 HY 57 Gy. J OST SRO S100 1 16000N be had 1000. 15 5333.33N ‘y 45 Hh -SMRIIN HRs ee -16000N Angle between secondary shear load and direct shear load on each Tivet Resultant shear load on rivet 1. 48 9s vee So R-M(ny (my +2c0890°xP x F = (5000) +.(16000)" +9 = 16763 Similarly, Osy Rony (4) = y(s000y' + (5333.33) = 7310 56N R,=R, = 7310.56N Ry = R, = 1676305 N Maximum shear load on rivet 1 and 4, Rend xr 4 oF, 16763.05 =F ed? «140 d? =152.45 412.34 e14mm [Ans,]DESIGN OF MACHINE ttached to ah pracket is a orizontal aA in Figure. The maxi ‘olumn by m & angwn In Fis) MUM permissible nim of thre ical rivets: stress for the rivet is 60 + 100 10 {lee Dy) tT t . Y “ \Ge~ j) Which rivet is subjected to Maximum shear force? i) What is the magnitude f maxim ii) Determine the diametor of river” orem force? [WBUT 2014, 2017) Answer Given data: . =60Nimm'; h=3 P=25KN=25x10°N Direct stress on each rivet _P_ 25x10" Oy 38 ‘The centre of gravity could lie at B, Tuming moment produced by the load at B of the rivet system due to eccentricity =p: AB =25x10° x100 =2500x10°N—mm =8.3x10°N ~Fatcapy 2) Fa «px AB= A (4B) +(BC)] Fal2«c100y'] 9 2250x107 1003100 _ 959 109 N «9x (100)' As the secondary shear loads are proportional to their radial distances from the centre of gravity -.F,=0 [As F, isin the ‘B’] BC 100 Fos Bx = Bago = Fy =1250x10 Resultant load on each rivet R, =F, —P, =1250x10° -8.3x 10? =1241.7x10°N Ry = P, =8.3x10°N Ro = Fe +P, =1250x10° +8.3x10 =1258.3x10°N So, maximum shear force will be subjected to rivet 3. [Ans. (i)| Maximums shear force =1258.3x10°N =1258.3KN [Ans. (i)| DMET-81NS porucan PuBLICATIO! eter of rivet "idxt ara «60 =49.9=50mm iv) Width of cotter — failure of cotter in shear, P=2xbxtxr—> 30x10 = 2xbx10x35 > b= 43mm ¥) Dia. of socket collar Let, d, = dia. of socket collar P=(d,-d,)xtxo, DMET-85POPULAR PUBLICATIONS 23010" - (d,-10)1090 30%10" 900 od, 40 od, = 73.375" Vi) Thickness of socket collar Tet, C = thickness of socket collar P= 2d, -d,)xCxr 23010" = 2(75 40) x C35 2C=12mm ea, o to the en! Vii) Distance from the end of the aero the end of the rods Let, a= distance fromthe end of ot P= 2axd, x1 = 2ax 40x35 = 28000 3 q= 20x10 io zetimm 2800 Viii) Diameter of spigot collar Let, d, =dia of spigot collar P-A[ay-(ay Je. 3010 =f (a,) (40) Joo 2 _ go? 30210" x4 d} 40? = cared =424>d,=45mm ix) Thickness of spigot coller Let, t= thickness of spigot collar 3010" = ad, x4 xz 33010 =h= = x40 x1 35 6.8 say 8 mm x) The length f cotter ()=4a= 4x28=119 mm xi) The dimension eg taken as 2d, = 8= 33.60 34m TE 12x25 FE 5. im MET. 86DESIGN OF MACHINE ELEMENTS MODULE 6 the assembly of pulley, key and 1 Inthe fey i= made the weakest (weur 2009) | *) Koy is made the weakest \ ©) key is made the strongest \ )all the three are designed for equal strength answer (D) shaft made of ductile material is subjected to combined bending and twisting 2ifa i Zoments, which of the failure theory would give the conservative value? ay (BUT 2009] a) Maximum principal stress theory b) Maximum shear Secor ¢) Maximum strain energy theory 4) Maximum distortion energy theory answer: () 4, The centrifugal tension in belts [WBUT 2010} a) reduces power transmission b) increases power transmission ¢) does not affect power transmission 4) increases power transmission upto certain speed and then decreases Answer: (4) 4, Creep in belt drive is due to [WBUT 2010) a) material of the belt b) material of the pulley c) uneven tension and contraction due to varying tension d) expansion of the belt Answer: (d) 5. In V-belt drive, belt touches (WBUT 2012, 2018] a) at bottom b) at sides only c) both at bottom and sides d) could touch anywhere Answer: (b) 6. A bolt of M 24 x 2 means that (WBUT 2012, 2013] a) the pitch of the thread is 24 mm an\ b) the cross sectional area is 24mm? c) the nominal diameter is 24 mm and pitch is 2mm 4) the effective diameter of the bolt is 24 mm and there are two threads per cm. Answer: (c) id depth is 2mm DMET-87— > POPULAR PUBLICATIONS ft 7. Coupling and clutch connect two shat b) in motior Me, 2) atest inmotion respectively ¢) ll ofthe My, ) at rest Answer: (b) ignment between two shafts is py 8. When the possibility of misaige i op ry type of shaft coupling used is b) gear coupling Mig ‘, a) flexible aa 4) universal coupling <) rigid coupling wie f key, shaft coupling h, ists of key, ing hal 9. A shaft coupling een Seria weakest from et 3 Me . Which component shoul views? ‘ a) the coupling —_b) the shat Answer: (c) Ways c) the key r ’ : Y) the be 10. Universal coupling is used to connect two shafts which a BUT 2014 ‘ a) lateral misalignment b) exact algnment ¢) intersecting axes at a small angle) nol Answer: (c) jected to : . Mayr 11. ayes reer only b) combined bending moment ang ton ) twisting moment only d) none of these Answer: (c) 12. Oldham coupling is used to connect two shafts DWBUT 25, a) which is perfectly aligned 'b) which are not in exact alignment ¢) which has lateral misalignment 4) whose axis intersects at a small angle Answer: (c) 13. The centrifugal tension in belt a) reduces power transmission b) increases power transmission ¢) increases power: transmission upto certain ‘Speed then decreases d) does not affect Power transmission Answer: (2) [WBUT 20 14, Creep in belt drive is due to ae 8) Material of the belt ) Material ofthe pulley ¢) Uneven tension and contraction i i 3 Epon ofthe bat lon due to Varying tension Answer: (d) a DMET-88DESIGN OF MACHINE ELEMENTS disc clutch h - 3 discs on driving shaft and 2 discs on driver shaft. 16. pairs of contact 7 of PE surta Nu by2 93 {WBUT 2017] ewer (A) a4 6A euler Ser emear @ torque of 5 kNm. If the torque is reduced to 4 nm ther ending moment that can be applied to the shaft is 1 a) 1 kNm b) 2 KNm. c)3kNm ahentn nan Answer? (c) Short Ans ive, for maximut 4, In belt drive, fo IM power transmission, show thi third of the * jximum tension in the belt is absorbed as centrifugal pee “ [WBUT 2009, 2011, 2014, 2018] Answer? \ t Slack side 7 7, Tahtsde We know that the power transmitted by a belt, p=(1\-T)v 1, = Tension in the light side in N T)=Tension in the black side in M V = velocity of the left in m/s We know, eee Lyon A Pa Th ~Tayy =H a= c where, c=(1 DMET-89CATIONS porurar PUBLICA 10 be subjected in M s elt can We know that R-T ra ihe belt Maximum tension 1081 . on in cf centrifugal tension I per yee 4 a r.- mv’ | (omy wre { , = expression with respect ees ove expre o. ferentiate the For maximum power dill equal to 0. dp av or, Lary m'ye=0 av T-3m" =0 T-37.=0 = | ae the power transmitted is maximum, as centrifugal tension. [Proved] 0 1/3 rd of the maximum tension mm? is to subjected to static loag 2, Asal eat of ved ten Horan moment of 30 kN-m, Detem: = diameter of the shaft using maximum shear stress theory. Assume a fact safety is 2. DWBUT 2093 x Answer: Given data: 1,= 750 N/mm? M=10KN-m=10% 10°N-m=10* 10°N—mm T=30KN-m=30* 10°N-mm FS=2 Let, the diameter of the shaft be d. r, allowable shear stress r 750 =—=375N/mm? FS S N/mm‘ According to maximum shear stress theory “s equivalent twisting moment, rr T.=VMP +P = (010°) + (30%10°) = Jaox108 = 6324.5 Numm n 6324.5 =F xrnd? = ISxd! d? = 3221069 mm? 4 =31.8mm=32mm ,DESIGN OF MACHINE ELEMENTS ad {designed to tranamit 120 KW of the outside diam 105 rpm. The = ‘ Assuming fuameter Iculate the minimum required outside answer [WBUT 2010, 2016} N-10Stpm P-120KW d, 120 10'w 2d, ord, do 2 re 4S MPa~ 45 Nim? We know that torque transmitted by the shaft P60 12010 x 60 Dan Iexios 109!3-4N~m =10913.4%10? N— mm (a) ~@)" | fn r xx lo d 0 4\ caus (44) or, 10913.4« 10° = igxtsx wt") 6 a= »_di/\ a, ~Zxasr(a As) d} =1317487.16 : d,=109.6=110 mm [Ans.] 4, What is an axle? How does it differ from a shaft? [WBUT 2010, 2018] Answer: ‘An axle is a stationary machine element and is used for the transmission of bending moment only. It acts as a support for some rotating body such as heisting drum, a car wheel or a rope shear. It differs from shaft that it is used only for transmission of lending moment and it is stationary. 5. A parallel key is used to connect a pulley to a 45 mm diameter shaft. The standard cross-section of the key is 14mm x 9mm. The key is made of commercial steel (o,, = 230 N/mm?) and the factor of safety is 3. Determine the length of the key on basis of shear and compression considerations, if 15 kW power at 360 rpm is transmitted through the keyed joint. For the key material the yield strength in compressi to be equal to the yield strength in tension. pression can be assumed to | yi wBUT 2044) DMET-91POPULAR PUBLICATIONS Answer: 1=9mm onan w= 1mm: po ISkW=15 19, Gy = 230 N/mm’; Fey = 3: = 360 pm : Let length of the key be / 106615010 Torguetransmited, 7 = 2S yx«dWet . 6 = 397.8 N-m = 397.810" N-mm Working tensile stress o Conside ing shear on the key, xtxd? 16 397810? = Fx ry (45) x 16 2.23 Nimm? d “T=lxwxrx 2 OF, 397.8x 197 who14a23. 25483 “-1=56.8=57mm Now Considering crushing on the key as assumed, o, = a, t qd Telxing 4 2 m5 3 OF 397.810 1,50, 230, 45 2 an say length of the key = 52 mm (Ans.) ne ina ci penomena Of belt, : ™. drives a jj Bulley is 750 mm diam nd the Puley on erat eY chats raayenk Th sn Ss 5 dri q mm. A 900 mr Peed of dvnayes ane en Gameter pulley keyed 7 Answer: ou '8 a Slip of 2% at each Ima belt drive when the [WBUT 2017 the belt extend ang it cont froy ie to the tight side, Certain portion lt ight sidyy id Die Ne ie lave et there is a relative motion between the belt and the cw elt eps ne “ N,_d) B+ Jo N, d, E+ Jo, where 0, and cr, = Stress in the belt on the tight and slack side respectively E=Young’s modulus for the material of the belt Given data N, =150 rpm d, = 750mm 450mm 900 mm 150mm 5,=5,=% Now, ERENCE es xd, 100 100 y 750% 900 pour 450x150 100)" 100) 150x9.6=1440rpm [Ans.] 1.2) What is slip of the belt? How is it related with speed of pulleys? [WBUT 2013, 2015] y of 1.5m effective diameter y i r LV, of the circumference, surface is 0.3. Determine, given that 1) A flat belt is required to transmit 30 KW from a pulle gat 300 rpm. The angle of contact is spread ove between the belt and pulley into account, width of the belt required. It is 1 is 1100 kg/m* and related runnin, The coefficient of friction taking centrifugal tension it the belt thickness is 9.5 mm, density of its material permissible working stress is 2.5 MPa. [WBUT 2013] Answer: he belt and the pulleys becomes insufficient the 2) When the frictional grip of between 1! aoe notion ofthe driver occurs without carrying the belt with it This is called stip of the belt. The slip reduces the velocity ratio of the system. My ae 5) MN, d,+t\ 100 DMET-93PULAR PUBLICATIONS porul » 20H = 30810'H 15m N- 300m lines ° nf > 7" 360 = 168° =165x Aso 2.88 rad u=03 1 =9.5mm,=0.0095m P=1100 kg/m? o=2.SMPa=2.5x10°N é Im? Let, 7; = Tension in the tight of the belt T, = Tension int the slack side of the belt, We kn OW that the velocity of the belt, ya ZdM _xx15x300 =23.57 m/s GO ancora and power transmitted (p) 30x10? =O -Tv= (F-12357 © TT, =30x10°/23.57=1973y (1) We know that 23log (2) = HO=0.3x 2.88 = 0.864 2 T, 0.864 “ log] —t |= 9-864 = 0.3756 nel 23 T, t= 2.37 ven (2 or, r 5 (2) From equations (1) and (2), we find that 2199N 27 =926N Let, b = width We know that i of the belt required mass ofthe belt per meter length m= Area xlength x density =bxIxI xp = 50.0095 x1x1100 — 10.456 kg/m and centrifugal tension, 7, = my? = 10.456(23.57)2 We know that maximum tension in the belt, T=T +T, = Stress x Area — 0F5 2199 + 58056 = 2.5199 =5805 6 N *bx0.0095 = 237505 DMET-94VISE OF MAC HIDE ELENMES 1 vypih ANON toy Ae yt HTD 8 Ann hay for fiking @ pulley on the shaft, which 6 18 10 KW power at 200 rpm to shaft, The key and the factor of safety Is 3, Determine tho tn in aia tore ploy ta 0 ir atoo! ABCA, = 90 Nini’ the key te mn) ionne oF Iho key material the Nold jon can ved 10 HO equal (0 the yl atrength In tenelon en comeDUT 2014) von al ye som FS TOKW N= 200: ay KON! | B.S anda table We got For shall dlameter upto 40 mmm Joni P60 10610660 pou ony aye ngy 1 TEAON m= 477.4610" Nr We ko amis py EINE! eT) ; 4 1 126.66 Ninn petaw : 5 {ATIAGN IO! Ox10<02.93 5 0 om, 5 (1884 © 19mm Now, for crushing consideration 1 d es \ 16 50 of ATTAT 10! © Cx 8 126.66 (18.84 19mm an take the length of the key ¢ 19mm [Ans.] So, we 9. A flat belt is required to transmit 30 kW from a pulley of 1.5 m effective diameter unning at 300 rpm. The angle of contact is spread over 11/24 of the circumference, The coefficient of friction between the belt and pulley surface is 0.3. Determine, taking centrifugal tension into account, width of the belt required, It is iven that the bolt thickness is 9.5 mm, density of its material is 1100 kgim and related permissible working stress is 2.5 MPa. DMET-95 {WBUT 2015]s POPULAR PUBLICATION! Answer ‘ om KW 010 W do Sm 300 rpm ' : 2.88 rad 6 360-165" 165+ ay 24 “03 1° 9 Smm = 0.0095m 121100 kg/m 0-25 MPa 2.5710 N/m’ 4. T ~ Tension in the tight side T, = Tension in the slack side We know the velocity ofthe belt v= BN 7151300 _ 23.57m/s 0 6 and power transmitted ( P), 0x10 =(,-T,)v= (7, -1,)23.57 i-T, fel S11 2 Blog! z H-9=031288=0.864 0 log) = 0375 oe tL) 23 1, 4 <2395 7 1 2981 wd 7, =26N La, [= at patel tired in meters, Mar ofthe Jeng m= cheer a PM ta 10.456 Ky jm Centrifugas tension 7. 10.456(23, 57)? = 58055 mn son inthe gy, “ “Ts7, Stress + Area = gq bt OF 2199 4 5805 25110 xb9 = “237504 S80Sh — 2199 eal ee i orb =) 29, Width OF the belt 122mm (Ang } ™ OF 122m DMET-96i haft as. DESI pesign as! Per A.s ) Torque and bending” respectively, The load is applieg fatigue factor appli 40. OF MACHINE ELEMENTS E. based on the fo lowing data t following with light shock. F, shock at ‘or : " this case the combined » 3 plied ahs and the combined ne chat mat ane to torsional moment, 90s nee 310 Nimm’ lultimag a and elim ey ont Of 480 Nimm?, yield strength _ whichever ie mm’. Maximum shear stress, shel inimum). There is no keyway in the answer! 8 zr Given Data: ° T =400N~m M=120N-m K,=15 K,=1 On, = 480 N/mm? o, =310N/mm? o=250N/ mm? Com =0:305,,0F 0.18 S, Equivalent twisting moment T.=\(K, x MY +(K, x0? — (1.5x120F + (1x400y = ¢, ‘ow = 0.185, as it smaller than 0.18 =86.4N/ mm? 438.6N —m ©. 438.6107 “ae 86.4 <.d=0.29=%1mm [Ans] 11. A hollow circular shaft is being designed to transmit 45 kW at 500 rpm. The inside diameter of the shaft is 0.6 time of the outside diameter. Assuming that the allowable shear stress is 84 MPa, calculate the outside and inside diameters. Answer: p=45x10° W r=84N/mm? N=500 rpm Welnow, p=2#NE 60 DMET-97 (WBUT 2017)POPULAR PUBLICATIONS wry $0057 asx 10 60 880.43 Nm 850.43< 10° Nmim yg! We know, T n/\6r| | “) 2 Let. D=outer dia, d= inner dia. Inside dia. of the shaft (d)=0.6x Dmm a terrs(? d } 59.43x10° = 7/16 x 84x => 859.4310" = 2/16 x84x 0.8704D* D “. Inner dia. (d) = (0.6x 40) mm = 24mm +. Outer dia. of the shaft (D) is 40mm 12. It is required to design a flat key for used to connect a pulley to diameter shaft. The standard cross-section of the key is 14x9mm*. The key 1 of commercial steel (S, = Sc = 230 Nimm’) and the factor of safety is 3. Dots," the length of the key on the basis of shear and compression considerat;r”” 15kW power at 360 rpm is transmitted through the keyed joint. DweUT 2%, Answer: : 50, 5, Compressive stress o, = 2! = 230 - 76.67 Nimm? “FOS 3 Shear stress r= = 38.335 Nimm? Power p=2#NT 60 _ 60x15x10° =T= 2x1x360 =397.84x 10° N-mm Shear stress r= ae dl 2x 397.84x10° 50x14x/ => 38.335 = DMET-98OF MACHINE ELEME 19.65% 10mm 47 dhl 16.67 4° 397.8410) 505941 21° 46.12 — 47mm ive stress 0, pte ai key = 47mm} pength ¢ l Long Answer T, \esign bushed:in type of flexible coupling to connect a pump shaft to a bat ssa anemia 000 r.p.m. The everal torque is 2 por cont more than mean torque. The allowable shear and crushin 18 for shaft and key ntl a is 40 MPa and 80 MPa respecti jar stress for cast 5 MPa. Tho allowable bearin '9 Pressure for rubber bush is 0.8 N/mm’. The in of the shaft, key and pin is same, [WBUT 2010, 2014] Answer Given data: P=40KW =40x10W N-=1000 rpm = Tyag +0.25T yy 1 =40MPa=40N/mm? 7, =80 MPa=80N/ mm? 14 =1SMPa=15N/ mm? P,=0.8 N/mm? Let, diameter of the shaft = d _Px60 _ 40x10? x60 =A £3819 N-m aN 2xx1000 Maximum torque Tyg, =! 25%T yay =47TAN =m = 477.4x10° N mm Weknow, Fcrxd = 2 x40xd? 16 16 ATTA IO? = FAO? p AT ax 2 6 sree mx 40 d=39.3%40 mm [Ans. (i)] DMET-99POPULAR PUBLICATIONS We noourie number of pans (ny 4 wid 057M diameter of ping, dy pe Hor allowing bending stress induced Aiameter of the goin (cf) may be taken as 20 1m lng Ve enh ofthe gn af beast sameter bmn 3 threaded ecg ” im dive 0 the CANPRESSIFILLY OF the yy Tbh, y Hand coupling halt hy » standard nut and washer The enlarged portion og of 24 mm diameter On this portion, « brass bush of thickness 2mm is gp tush caries a rubber bush, Assuming the thickness of rubber tah 4, 6m," Of rubber bush d, = 2462225226 - 40mm iu MAny (i, and diameter of the pitch circle of the pins 4 DW sd, 6276 2AAVS AD NZ N82 he diaries Ans, fy Vet J length of the bush in the flange. 41 We know that the bearing load acting on each pin, Wee Prd, e108 A021 08/4071 «Fal M y), Toca Wns 2 42 or, ATTA 10! savor" or, 6 37.6% 38mm and W320 32738 1216N ‘Ax the pin and the rubber bush are not rigidly held in the left hand flange, theres. tangential load (W) at the enlarged portion will exert a lending action on the pin, Maximum lending moment on the pin MN = W(Y6 95) 1216(394 +5) = 29184. — mm Section modulus Z» (d,)! » “1 (20)' «785.4 mm’ 32 32 , Bending stress, 0 = M2184 «97.15 0 / mm? 2 785.4 Maximum principal stress id tVo?4 ae? | : { 37.154 JG7.15) +476 Now, direct stress due to pure tension in the coupling halves Ww 1216 5 pat FS 213.87 Nm “dy 174 4 (20) Maxiniun principal stress } 91.15-4.(37.15)' + 443.877 | = 37.54.N mm DMET-100ESIGN OF Macay um shear stress asi aed ? I ang, seb") = Outer diameter of bug 2d =2*40=80mm snofthe hub = T=1.5d =1,5 49 _ num torque transmitted (7. ) vant 60mm oa ; 74x10 =x, Di-d' oy 1, =5.06MPa ce the induced shear stress for the hub material sin t ye of SMP, therefore the design of hub is ae iron) is less than the permissible we ekness of flange (ty) is taken as 0.54 1 0.Sd = 0.540 = 20mm D =o xt, xt, 2 2 or, 477.4x10° ow, 1x20 of, t) =2.37 MPa isles than permissible shear stress 1SMPa, So, the design is safe 2. A bearing housing shown in the Figure 4 is fastened to a frame by 6 bolts from the frame. Determine the size having yield strength of 245 Nimm? ar of the bolts. The material of the bolt is C20 IWBUT 2010] ind factor of Safety is 3, i<— 215 —>| SOKN mn DMET-101POPULAR PUBLICATIONS Answer: Given Data: d= 250mm => r=125mm 245 _ 81.67 /mm? 3 Let, d. = core diameter of the bolts As the bolts are equally spaced, the maximum load on the bolts ed 150+12 180 WL Reren( 82) 2450310 «250 170 *125cos| Spe | ne | Re 6 2 (150) + (125) =17749.36N Maximum load on the belt 5 W,=7d)o, fj 4 i.) 9, or, 1749.36 =x(aF 81.67 or, (d,)? = 276.711 4, =16.63mm From standard table of valu les of standard core diameter d. belt size M18, [Ans,] =16.376 and correspond 3. A solid circular shaft is subjected to a bending moment of 3000 N-m and: torque of 10000 N-m. The shaft is made Of 45C8 steel having ultimate tensile stress of 700 MPa and an ultimate sh na catress Of 800 MPa. Assuming a factor of safety a5 6, determine the diameter of the shaft. [WBuT 2014] Answer: Given data: M =3000N-m =3x10°N-mm T = 10000 N- 0x10°N-mm Ou = 700MPa = 700 N/mm? DMET-102 a2 DESIGN ¢ sonra = $00 Nit NGN OF MACHINE LLLMENT ‘0 6 censile stress 0, = 7H } pe wo" 6 116.7 Nimm 500 sie shear stress ==" => . io” Fy, 6 883. Nimm’ ppiameter of the shaft sr rdind ® maximum shear stress theory, ¢ mum se quivalent twisting mome We =\(3x10') + (10«10°) 10.4410 = mm carad! or, 10.44 x10° - 7 Teeth beal 16 63801 x10° mi to maximum according 0 0" \ 21(M+YM no mum, ral Stress theory equivalent bending moment qT?) == )=s0r+n) _U (said +10.44x10") =6.72x10°N-mm or, 6.72x10" =x 116.14 j-8.7mm ope Ting larger of the two values 4-86 [Ans.] 4, Aline shaft supporting two’ pulleys A and B is shown in figure. Power is supplied to the shaft by means of a vertical belt on pulley A which is then transmitted to pulley B carrying a horizontal belt. The ratio of belt tensions on tight and loose sides is 3:1 ‘and the maximum tension in either belt is limited to 2.7 KN, The shaft is made of plain carbon steel 40C8 (0, = 650Mpa and r,, = 380MPa). The pulleys are keyed to the shaft. Determine the shaft diameter according to ASME code if K, =1.5 and K,=1.0. DMET-103POPULAR PUBLICATIONS 1500, 4250 B 455 200 sx N respectively, Bur 2, Lengths and forces indicated are in mm and mth, ay Answer: AC = 450mm; AD = 450mm; BD= 450m. of pulley A SOmm. Diameter of pulley B evel belt, at pulley A, 7, = Z700N. tension on vertical belt, pull S00N, tension on vertical belt, slack side pulley A = L500N, tension on horizontal belt at pulley B Ze SOON, tension on horizontal bel, slack side pulley B $=30°: ©, = 650 Mpa; % =380 MPa Kris, Kw i9 Tatio=3: Vertical load acting on shaft at 4 Wo = +7, =2700+900 =3600N oad acting on shaft at A= 9 Torque acting on pulley 4 00 g T(r ~1)% = 2100-50) 258 = a ~225000 N m= 225N-m Components of T; . Horizontal Ty =1500xeos30°~ '300N;. Vertical 7, 500xsin30°— 759 Components of T, Horizontal 7, ~500xcos30°= 433; Vertical 7, = 500 x sin30°~ 250N Torque acting on pulley p D, 4 =(L, E009) "8507S N-mm = 195.075 Nn Vertical load Scting on shaft at B =(b, +1, )=(750+250) ~ 000 Horizontal load acting on shaft at B=(T, + Ty) = (13004 433) =1733N DMET-194 7