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Roll No:
(To be filled in by the candidate)
PSG COLLEGE OF TECHNOLOGY, COIMBATORE - 641 004
SEMESTER EXAMINATIONS DECEMBER-2018
BE / BE (SW) – MECHANICAL ENGINEERING Semester : 5/7
15M502 DESIGN OF MACHINE ELEMENTS
Time : 3 Hours Maximum Marks : 100
INSTRUCTIONS:
1. Answer ALL questions. Each question carries 20 Marks.
2. Subdivision (a) carries 3 marks each, subdivision (b) carries 7 marks each and subdivision
(c) carries 10 marks each.
3. PSG DESIGN DATA BOOK is permitted

1. a) It is required to standardize 11 speeds from 72 to 720 rpm for a machine tool. Specify
the speeds.
b) A C-frame subjected to a force of 15 kN is shown in Fig.1. It is made of grey cast iron
FG 300 and the factor of safety is 2.5. Determine the dimensions of the cross section
of the frame.

Fig.1 Fig 2
c) A wall bracket with a rectangular cross-section is shown in Fig.2. The depth of the
cross-section is twice of the width. The force P acting on the bracket at 60° to the
vertical is 5 kN. The material of the bracket is grey cast iron FG 200 and the factor of
safety is 3.5. Determine the dimensions of the cross-section of the bracket. Assume
maximum normal stress theory of failure.
2. a) List the three modes of crack opening with neat sketch.
b) A rectangular plate, 15 mm thick, made of a brittle material is shown in Fig.3.
Calculate the stresses at each of three holes of 3, 5 and 10 mm diameter.

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Fig.3.
c) A solid circular shaft made of steel Fe 620 (Sut = 620 N/mm2 and Syt = 380 N/mm2)
is subjected to an alternating torsional moment, which varies from –200 N-m to + 400
N-m. The shaft is ground and the expected reliability is 90%. Neglecting stress
concentration, calculate the shaft diameter for infinite life.The factor of safety is 2.
Use the distortion energy theory of failure.
3. a) Classify keys which are used to connect shafts and coupling. Sketch a feather key.
b) The following specifications are given for a rigid coupling: outer diameter of flanges =
160 mm, diameter of recess = 95 mm, number of bolts = 6, pre-load of each bolt = 10
kN, coefficient of friction = 0.15, speed of rotation = 100 rpm, the bolts are fitted in
large clearance holes. Calculate the power transmitting capacity of the coupling.
c) i) A transmission shaft, supporting two pulleys A and B and mounted between two
bearings C1 and C2 is shown in Fig.4. Power is transmitted from the pulley A to B.
The shaft is made of plain carbon steel 45C8 (Sut = 600 and Syt = 382 N/mm2).
The pulleys are keyed to the shaft. Determine the shaft diameter using the ASME
code if, kb=1.5 and kt= l. Also, determine the shaft diameter on the basis of
torsional rigidity, if the permissible angle of twist between the two pulleys is 0.5°
and the modulus of rigidity is 79400 N/mm2

Fig.4
(OR)
ii) In an automotive plate clutch, six helical compression springs arranged in parallel
provide the axial thrust of 1800 N. The springs are compressed by 12 mm to
provide this thrust force. The springs are identical and the spring index is 6. The
springs are made of cold-drawn steel wires with ultimate tensile strength of 1300

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2
N/mm . The permissible shear stress for the spring wire can be taken as 50% of
the ultimate tensile strength (G = 81370 N/mm2). The springs have square and
ground ends. There should be a gap of 1 mm between adjacent coils when the
springs are subjected to the maximum force. Design the springs and calculate: (i)
wire diameter; (ii) mean coil diameter; (iii) number of active coils; (iv) total number
of coils; (v) solid length; (vi) free length; (vii) required spring rate; and (viii) actual
spring rate
4. a) What are the advantages of square threads over trapezoidal threads?
b) A bracket, as shown in Fig.5. is welded to a plate. The welds have the same size,
and the permissible force per mm of the weld-length is 1 kN. Calculate the lengths l1
and l2.

Fig.5 Fig.6
c) A bracket is attached to a vertical column by means of six identical rivets as shown in
Fig.6. It is subjected to an eccentric force of 60 kN at a distance of 200 mm from the
centre of the column. The maximum permissible shear stress for the rivets is 150
N/mm2. (i) Which rivet is subjected to maximum shear force?(ii) What is the
magnitude of maximum force? (iii) Determine the diameter of rivet.
5. a) List at least six different kinds of rolling contact bearing
b) A transmission shaft, transmitting 8 kW of power at 400 rpm from a bevel gear G1 to
a helical gear G2 and mounted on two taper roller bearings B1 and B2 is shown in
Fig.7. The gear tooth forces on the helical gear act at a pitch circle radius of 55 mm,
while those on the bevel gear can be assumed to act at the large end of the tooth at
a radius of 50 mm. The diameter of the journal at the bearings B1 and B2 is 40 mm.
The load factor is 1.2 and the expected life for 90% of bearings is 10000 h. Bearings

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B1 and B2 are identical. The thrust force due to bevel and helical gears is taken by
the bearing B2. Select suitable taper roller bearings for this application.

Fig.7.

c) The following data is given for a 360° hydrodynamic bearing: bearing diameter =
50.02 mm, journal diameter is 49.93 mm, bearing length = 50 mm, journal speed =
1440 rpm, radial load is 8 kN, viscosity of lubricant is 12 cP The bearing is machined
on the lathe from bronze casting, while the steel journal is hardened and ground. The
surface roughness (cla) values for turning and grinding are 0.8 and 0.4 microns
respectively. For thick film hydrodynamic lubrication, the minimum film thickness
should be five times the sum of surface roughness values for the journal and bearing.
Calculate (i) the permissible minimum film thickness; (ii) the actual film thickness
under operating conditions; and (iii) power lost in friction.

/END/
FD/JU

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