Register No.

BE/B.Tech Degree Examination , May 2024

Sixth Semester

20MET63 – DESIGN OF MACHINE ELEMENTS

(Regulations 2020)

Time : Three hours Maximum : 100 Marks

Answer all Questions

PART – A (10 X 2 = 20 Marks)

1. Define endurance limit. What are all the factors affecting endurance strength [CO1,K1]
2. Sketch goodman and soderberg diagram and locate safe design region [CO1,K2]
3. Classify the types of keys. [CO2,K2]
4. Two blocks diametrically opposite to each other are used in a block brake. Why? [CO2,K2]
5. List some types of commonly used thread forms. [CO3,K2]
6. When will the weld deposit be weaker? [CO3,K2]
7. What is solid length in a spring? [CO4,K2]
8. Why heat dissipation is necessary in clutches? [CO4,K2]
9. How can be the equivalent loads in a bearing is calculated? [CO5,K2]
10. Define coefficient of fluctuation of speeds in case of flywheels. [CO5,K2]

PART – B (5 X 16 = 80 Marks)
11. a. i) An offset link subjected to a force of 25 kN is shown in Fig. It is made of grey cast iron [CO1,K3]
FG300 and the factor of safety is 3. Determine the dimensions of the cross-section of the
link.

ii) The frame of a hacksaw is shown in Fig. The initial tension P in the blade should be 320
N. The frame is made of plain carbon steel 30C8 with tensile yield strength of 440 N/mm 2
and the factor of safety is 3.5. The cross section of the frame is rectangular with a ratio of
depth to width as 4, as shown in Fig. Determine the dimensions of the cross-section.

(Or)
11. b. i) A machine component is subjected to fluctuating stress that varies from 40 to 90 N/mm 2. [CO1,K3]
The corrected endurance limit stress for the machine component is 290 N/mm 2. The
ultimate tensile strength and yield strength of the material are 560 and 400 N/mm 2
respectively. Find the factor of safety using
(1) Gerber theory
 (2) Soderberg line
(3) Goodman line
Also, find the factor of safety against static failure.

ii). A steel member is subjected to a 3 dimensional stress system and the resulting principal
stress are 122 N/mm2 tension, 88 N/mm2 and 44 N/mm2 compression. If the proportional
limit of the material in simple tension is 280 N/mm2 and its poissons ratio is 0.3. determine
factor of safety according to a) Maximum principal stress theory
b) Maximum principal strain theory and
c) Maximum shear stress theory

12. a. i) Determine the required standard diameter of a uniform circular shaft carrying 2 pulleys [CO2,K3]
of weight 2.3 kN each. The shaft 750 mm long is supported at the end and carries 2 pulleys
at 250 mm and 500 mm from the left end. Pull on the right pulley is 10 kN vertically
downwards. The shaft transmits a torque of 3.6 kN-m between the pulleys. Assume
kb=kt=1.5 and allowable shear stress of 77 N/mm2

ii) It is required to design a square key for fixing a gear on a shaft of 25 mm diameter. The
shaft is transmitting 15 kW power at 720 rpm to the gear. The key is made of steel 50C4
(Syt = 460 N/mm2) and the factor of safety is 3. For key material, the yield strength in
compression can be assumed to be equal to the yield strength in tension.Determine the
dimensions of the key.
(Or)
12. b. i) A 400 mm radius brake drum contacts a single shoe as shown in fig. and sustains 222 N- [CO2,K3]
m torque at 555 rpm. For a coefficient of friction 0.25, determine:
1. Normal force on the shoe.
2. Required force F to apply the brake for clockwise rotation.
3. Required force F to apply the brake for counter clockwise rotation.
4. The dimension c required to make the brake self-locking, assuming the other
dimensions remains the same.
5. Heat generated.

ii) The layout of a double block brake is shown in fig. The brake is rated at 255N.m at 655
r.p.m. The drum diameter is 250mm assume coefficient of friction to be 0.3 and for
conditions of service a pv value of 1000(kpa) m/s may be assumed.
Determine
(a)Spring force S required to set the brake and
(b)Width of shoes
(c)Which shoe will have greater rate of wear and what will be the ratio of rates of wear of
the two shoes?
13. a. i) The following data is given for the bracket illustrated in Fig. [CO3,K3]

P = 55 kN, e = 60 mm, l 1 = 150 mm l2 = 25 mm There is no pre-load in the bolts. The bolts

are made of plain carbon steel 45C8 (Syt = 480 N/mm2)
and the factor of safety is 2.5. Using the maximum shear stress theory, specify the size of
the bolts.

ii) Find suitable bolt for the application shown in Fig.

(Or)
13. b. i) A steel plate, 100 mm wide and 10 mm thick, is joined with another steel plate by means [CO3,K3]
of single transverse and double parallel fillet welds, as shown in Fig. The strength of the
welded joint should be equal to the strength of the plates to be joined. The permissible
tensile and shear stresses for the weld material and the plates are 77 and 55 N/mm 2
respectively. Find the length of each parallel fillet weld. Assume the tensile force acting on
the plates as static.
 ii) A bracket is welded to the vertical plate by means of two fillet welds as shown in Fig.
Determine the size of the welds, if the permissible shear stress is limited to 86 N/mm2.

14. a. i) A helical compression spring is used to absorb the shock. The initial compression of the [CO4,K3]
spring is 33mm, and it is further compressed by 55mm while absorbing the shock. The
spring is to absorb 255kJ of energy during the process. The spring index can be taken as 6.
The spring is made of patented and cold drawn steel wire with an ultimate tensile strength
of 1500 N/mm2 and modulus of rigidity of 81370 N/mm2. The permissible shear stress for
the spring wire should be taken as 30% of the ultimate tensile strength. Design the spring
and calculate. (i) Wire diameter (ii) Mean coil Diameter (iii) Number of active turns (iv)
Free length (v) Pitch of turns

ii) A semi elliptic leaf spring used for automobile suspension consists of three extra full-
length leaves and 16 graduated leaves including the master leaf. The centre to centre
distance between two eyes of the spring is 1.5m. The maximum force acting on spring is
100 kN. For each leaf the ratio of width to thickness is 7:1. E=222 GPa, the leaves are pre-
stressed in such a way that when the force is maximum, the stresses induced in all leaves
are same and equal to 453MPa. Determine (i) the width and thickness of leaves, (ii) the
initial nip; and (iii) the initial preload required to close the gap C between extra full-length
leaves and graduated length leaves.
(Or)
14 b. i) Design a single plate clutch consist of two pairs of contacting surfaces for a torque [CO4,K3]
capacity of 222 N-m. Due to space limitation the outside diameter of the clutch is to be
250mm

ii) A Multiple plate clutch has steel on bronze is to transmit 9 KW at 1440 rpm. The inner
diameter of the contact is 80mm and outer diameter of contact is140 mm. The clutch
operates in oil with coefficient of friction of 0.27. The overage allowable pressure is
0.55Mpa. Assume uniform wear theory and determine the following.
a) Number of steel and bronze plates
b) Axial force required
c) Actual maximum pressure

15 a. i) A Ball Bearing works on following work cycle [CO5,K3]

Sl. NoRadial Speed (rpm) Element

load time %
(kN)
1 3001 720 30
2 7010 1440 50
3 5100 900 20
The Dynamic Load carrying capacity of the bearing is 16.6 KN. Consider work cycle on
One Minute revolution.

Calculate :

 Average speed rotation

 Equivalent radial load
 The Bearing Life in Hours.

ii) Following data are given for a 360º hydrodynamic bearing:

 Radial load=3.2 kN , Journal speed= 1490 r.p.m, Journal diameter=50 mm , Bearing
length=50mm , Radial clearance=0.05 mm , Viscosity of the lubricant= 25 cP.
Assuming that the total heat generated in the bearing is carried by the total oil flow in the
bearing, calculate:
• Power lost in friction;
• The coefficient of friction;
• Minimum oil film thickness
• Flow requirement in 1/min; and
• Temperature rise.

(Or)
b. i) A multi-cylinder engine is to run at a constant load at a speed of 500 r.p.m. On drawing [CO5,K3]
the crank effort diagram to a scale of 1 m = 254 N-m and 1 mm = 3º, the areas in sq mm
above and below the mean torque line are as follows: + 166, – 177, + 168, – 191, + 197, – 162
sq mm. The speed is to be kept within ± 1% of the mean speed of the engine. Calculate the
necessary moment of inertia of the flywheel. Determine suitable dimensions for cast iron
flywheel with a rim whose breadth is twice its radial thickness. The density of cast iron is
7250 kg/m3, and its working stress in tension is 6.8 MPa. Assume that the rim contributes
92% of the flywheel effect.

ii) The turning moment diagram for a petrol engine is drawn to the following scales:
Turning moment, 1 mm = 12N-m; Crank angle, 1 mm = 1º. The turning moment diagram
repeats itself at every half revolution of the engine and the areas above and below the
mean turning moment line, taken in order are 295, 685, 40, 340, 960, 270 mm 2. Determine
the mass of 300 mm diameter flywheel rim when the coefficient of fluctuation of speed is
0.3% and the engine runs at 1888 r.p.m. Also determine the cross-section of the rim when
the width of the rim is twice of thickness. Assume density of rim material as 7250 kg /m3.