GTU STUDIES

MECHANICAL ENGINEERING DEPARTMENT

Subject: Design of Machine Elements

Subject code: 3171917
Important Numerical Questions

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Chapter 1 – DESIGN CONSIDERATION
What are preferred numbers? The maximum & minimum load carrying capacities of
1 dumpers in a manufacturing unit are 40 KN and 630 KN respectively. The company is
interested in developing seven models in this range. Specify their load carrying capacities.
Chapter 2 – DESIGN OF COUPLING
Design a cast iron protective type flange coupling to transmit 15 kW power at 900 r.p.m
from an electric motor to a compressor. The service factor may be assumed as 1.7. The
permissible stresses are as follows.
1. Shear stress for shaft, bolt and key = 40 MPa
1 2. Crushing stress for bolt and key = 80 MPa
3. Shear stress for cast iron flange = 8 MPa
Standard shaft diameters are:
20, 22, 24, 26, 28, 30, 32, 34, 36, 38, 40
Take number of bolts as 3.
Design and draw a protective type of cast iron flange coupling for a steel shaft
transmitting 15 kW at 200 r.p.m. and having an allowable shear stress of 40
MPa. The working stress in the bolts should not exceed 30 MPa. Assume that
2
the same material is used for shaft and key and that the crushing stress is twice
The value of its shear stress. The maximum torque is 25% greater than the full
Load torque. The shear stress for cast iron is 14 MPa.
CHAPTER 3 – DESIGN OF SPRINGS
Design a close coiled helical compression spring for a service load ranging from 2250 N to
2750 N. The axial deflection of the spring for the load range is 6 mm. Assume a spring
1
index of 5. The permissible shear stress intensity is 420 N/mm2 and modulus of rigidity, G
= 84 kN/mm2.
A semi-elliptic leaf spring used for automobile suspension consists of three extra full-length
leaves and 15 graduated-length leaves, including the master leaf. The center to center
2 distance between two eyes of the spring is 1 m. The maximum force that can act on the
spring is 75 kN. For each leaf, the ratio of width to thickness is 9:1. The modulus of elasticity
of the leaf material is 207000 N/mm2. The leaves are pre-stressed in such a way that when
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the force is maximum, the stresses induced in all leaves are same and equal to 450 N/mm2.
Determine (i) the width and thickness of the leaves; (ii) The initial nip.
Design a leaf spring for following specification:
Total load = 14 tonnes
Numbers of springs supporting the load = 4
Maximum number of leaves = 10
3
Span of the spring = 1000 mm
Permissible deflection = 80 mm
Take Young Modulus = 0.2x106 N/mm2,
Allowable stress in spring material = 600 N/mm2.
Design a helical compression spring for a maximum load of 1000 N for a deflection of 25
4 mm using the value of spring index as 5. The maximum permissible stress for spring wire
is 420 N/mm2, and modulus of rigidity is 84 KN/mm2.
CHAPTER 4 – DESIGN OF PRESSURE VESSEL
A closed vessel is to be designed to withstand an internal pressure of 5 MPa having inside
diameter of 450 mm. The properties of the vessel material are yield strength is 300 MPa,
1 ultimate tensile strength is 500 MPa, Poisson’s ratio = 0.3. Determine the required wall
thickness of the vessel using a factor of safety of 1.5 based on yield strength on the basis
of i) maximum principal stress theory, ii) maximum shear stress theory.
The cover of a cylindrical pressure vessel made of cast iron. The inner diameter of the
cylinder is 500 mm and the internal pressure is limited to 2 MPa. The cover is fixed to the
cylinder by means of 16 bolts with a nominal diameter of 20 mm. Each bolt is initially
tightened with a preload of 20 kN. The bolts are made of steel FeE 250 having yield stress
2
= 250 N/mm2. The Young’s module of elasticity for steel, cast iron and zinc is 207 kN/mm2,
100 kN/mm2 and 90 kN/mm2 respectively. Determine the factor of safety for bolts
considering the effect of the gasket. Assume thickness of cylinder cover, cylinder flange
and zinc gasket is 25 mm, 25 mm and 5 mm respectively.
A hydraulic cylinder with closed ends is subjected to an internal pressure of 15 MPa.
The inner and outer diameters of the cylinder are 200 mm and 240 mm respectively.
3
The cylinder material is cast iron FG300. Determine the factor of safety used in design. If
the cylinder pressure is further increased by 50%, what will be the factor of safety?
Chapter 5 – Design of Rolling contact Bearing
Find the rating life of the 50 mm bore, light series, ball bearing under 6800 N radial load at
1 600 rpm. The load is out of balance and rotates with inner ring. Assume there is no shock
loading.
A bearing is subjected to the following work cycle: radial load of 4450 N, 6675 N and
2225 N at 150 rpm, 600 rpm, and 300 rpm for 30 % of time, 10 % of time, and for
2 remaining time of the cycle respectively. The inner ring rotates and the loads are steady.
Find the expected life of this bearing in hours, by considering the static and dynamic load
carrying capacities of the bearing as 10013 N and 14952 N respectively.
A deep groove ball bearing has a rated static and dynamic load capacity of 4150 N
3 and 4750 N respectively. The bearing has to take an axial load of 2075 N and a radial load
of 4000 N. Find the expected life of the bearing.

Prepared by: Prof. Vishal Patel - 8200696240

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Bhavnagar
Sr. GTU
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A single row deep groove ball bearing No. 6002 is subjected to an axial thrust of 1000
4 N and a radial load of 2200 N. find the expected life that 50% of the bearings will complete
under this condition.
Chapter 6 – Design of Sliding contact Bearing
A 360° hydrodynamic bearing operates under the following conditions:
radial load = 50 kN journal diameter = 150 mm
bearing length = 150 mm radial clearance = 0.15 mm
1
minimum film thickness = 0.03 mm viscosity of lubricant = 8 cP
What is the minimum speed of operation for the journal to work under
Hydrodynamic conditions?
A full journal bearing of 50 mm diameter and 100 mm long has a bearing pressure
of 1.4 N/mm2. The speed of the journal is 900 r.p.m. and the ratio of journal diameter to the
diametral clearance is 1000. The bearing is lubricated with oil whose absolute viscosity at
2 the operating temperature of 75 °C may be taken as 0.011 kg/m-s. The room temperature
is 35 °C. Find: 1. The amount of artificial cooling required, and 2. The mass of the
lubricating oil required, if the difference between the outlet and inlet temperature of the oil
is 10°C. Take specific heat of the oil as 1850 J / kg / °C.
CHAPTER 7 – DESIGN OF GEAR DRIVE
A pair of bevel gears consists of a 30 tooth pinion meshing with a 48 tooth gear. The axes
of the connecting shafts are right angles to each other. Assume the module of the gears to
be 5 at the larger end. Calculate:
1. The pitch circle diameters of pinion and gear.
1
2. The pitch angles of pinion and gear.
3. The cone distance.
4. The mean radii of the pinion and gear.
5. Back cone radii of the pinion and gear.
Considering static strength determine a suitable module and face width for a pair of helical
gears that transmit 15 kW. The teeth are 20° stub in diametral plane and have a helix angle
of 45°. The pinion runs at 10 000 r.p.m. and has 80 mm pitch diameter. The gear has 320
2
mm pitch diameter. The gears are made of cast steel having allowable static strength of
100MPa. Assume endurance strength of gear material = 618 MPa.
Also, check the gears for wear.
Design a pair of straight teeth spur gears to transmit 20 kW when the pinion rotates at 300
r.p.m. The velocity ratio is 1:3. The allowable static stresses for the pinion and gear
materials are 120 MPa and 100 MPa respectively. The pinion has 15 teeth and its face width
3
is 14 times the module. Assume steady load condition and 8-10 hours of service per day.
Take, the tooth form factor, y = 0.154 − (0.912 / No. of teeth); and the velocity factor, Cv
= 3 / (3 + v).
A worm and worm wheel gear drive is designated as 2 / 41 / 10 / 8. The drive is used to
obtain a speed reduction of 20.5 from an input speed of 1450 rpm. Material of the worm
4
wheel is Sand Cast and Chilled Phosphor Bronze, while the worm is made of Case-hardened
alloy steel. Determine the power transmitting capacity of the drive based on beam strength.

Prepared by: Prof. Vishal Patel - 8200696240

GTUSTUDIES ENGINEERING CLASS
Bhavnagar
Sr. GTU
Detail
No. Year
Design a pair of CI spur gear to transmit 12 kW having pinion speed of 200 rpm. The speed
reduction required is 2:1. Assume face width as 3 times circular pitch. The minimum
number of teeth on pinion is 24. Check your design in all failures considering the following
5 data;
Pressure angel 14.50 full depth involute, Factor of safety 1.5. The modulus of elasticity for
pair is 0.8 * 105 N/mm2, Error in manufacturing is not to exceed 0.05 mm, Allowable
bending stress for CI as 45 N/mm2, Surface endurance stress as 280 N/mm2.
Chapter 8 – Design of Gear Box for Machine Tools
Draw the structure and speed diagram for a gearbox having operating speed range from
31.5 rpm to 560 rpm. Use R4 series, with standard spindle speeds, the gearbox is
1.
connected to a motor driven by a pair of pulleys. Assume the motor speeds to be 1440
rpm. Draw the gearbox layout diagram.
Find the range ratio, geometric progression ratio and spindle speeds for the following data:
2. Nmin = 100 r.p.m., Nmax = 1800 r.p.m. and number of speed steps = 8. Also, draw all
possible structure diagrams.
Draw layout diagram of gear box, ray diagram and speed chart for a multi-speed gear box
of a radial drilling machine required to give eight steps. The power from motor to the
3.
input shaft of gear box is transmitted by a V-belt drive with a speed reduction of 1:6. The
minimum and maximum spindle speeds are 70 rpm and 1800 rpm respectively.
Chapter 9 – Design Mechanism
Design the crane hook of a hoisting block for a maximum load lifting capacity of 10 ton.
1 The material for hook is forged for which permissible tensile stress may be taken as 120
N/mm2. Use the modified triangular section for hook.
A crane is lifting a load of 25 kN through a wire rope and a hook. The weight of hook, etc.
is 15 kN. The rope drum diameter may be taken as 3 times the diameter of the rope. The
load is to be lifted with an acceleration of m/s2.Calculate the diameter of the wire rope.
2
Take f.o.s. of 6 and Young’s modulus for the wire rope 80 kN/mm2. The ultimate stress may
be taken as 1800 Mpa. The cross-sectional area of the wire rope may be taken as 0.38 times
the square of the wire rope diameter.
A crane hook having an approximate trapezoidal section is shown in Figure 1. The hook is
made of plain carbon steel 45C8 (yield strength = 380 MPa) and the f.o.s. is 3.5. Determine
the load carrying capacity of the hook.

Prepared by: Prof. Vishal Patel - 8200696240

GTUSTUDIES ENGINEERING CLASS
Bhavnagar
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