CHHATTISGARII SWAMI VIVEKANAND TECHNICAL

UNIVERSITY, BHILAI (C G)
Semester: V th Branch: Itlechanical Engg,
Subfect Machine Design - |

Note: 1) De.sign data book by PSG and ISI dala sieefs are allowed in the examination.
2) The duntion of the paper is 1(four) hours.

UNIT- I

General Gonsiderations S
Selection of Materials, Design Stress, Factor of Safety, Stress concentration factor in tension, bending and torsion,
theories of failures.
Notch sensitivity, design stress for variable and repeated loads, fatigue stress concentration factor, endurance
diagrams.

Ghain Drives
Chain drives, roller chains, geometric relationships, dimensions of chain components polygonal effect, power rating
of roller chains.

UNIT- II

Basic Elements Design

Types of key and design, design of socket-spigot cotter joint, sleeve and cotter joint, gib and Cotter joint, design of
Knuckle joint, design of splines.

uNrT- ilr

Threaded fastenerc:
Geometry of thread forms, terminology of screw threads and thread standards, specifications of steel bolts, initial
tension, relation between bolt tension and torque, design of statically loaded tension joints, design of bolted joints
due to eccentric loading.

Power $crews
Poper screws, Force analysis-square and trapezoidal threads, Collar friction, Stresses in screw, coefficient of
friction, efficiency of thread.

UNIT - IV

Riveted Joints
Types of rivet heads, types of riveted joints, failure of riveted joint, strength of rivet joint, efficiency of riveted joint,
design of riveted joint for boiler.

Welded joint .rr ?- {t Q,Lrnt-''t:. ''

Types of welded joints, stresses in butt and fillet welds, strength of welded joints, location and dimension of weld
design, eccentrically loaded joint, welded joint subjected to bending moment, design procedure, fillet welds under
varying loads, stress relieving techniques.

UNIT-V
Shaft and Axles
Transmission shaft, Design against static load, Design for strength, rigidity and stiffness, design under continuous
loading for fatigue"

Gouplings
Types of couplings, design of flange and flexible couplings, compression coupling, muff coupling.
 --E7

Class test 2 Machine Design 1

sth semester, Mechanicat Engineering 26.',io.09
$ol'le any two parts of the following. Assume suitable data wherever necessary:
: Qu.1. Determine the throat and leg dimensions for the welds of an eccentrically loaded bracket welded to the support as shown in
Figure. The permissible shear stress for the weld material is 55 lt/mm2.g,
Qu.2. Design a cotter joint to support an axial load of Za fglfne mglerial for;gll the components of the joint is steel with the
allowable stresses in tension, compression and shear as 50 N/ffi2, 60 l,ilmm2 anffss N/mm2.g.
Qu. 3. Determine the kgy dimensions for the following conditions. Ultimate shearing stre$s for the key material is 356 Ulmm2 wittr
factor of safety 5. Take rs = 0.4 oc.
h. Shaft diameter-O.09m, shearing resistance of the material of shaft and key are same.
i. Shaft dia-1 00mm rotating at 1 00 rpm transmits 224 kW. Power is taken through a gear with hub length 200mm.

.r
;

Te
.Y
\Lr
'i' '!,1'
,- {_,
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) r.y"
"'-kQ
- q
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t dtoc+'
tr qi* #*
a"

j,L'
t 6lt3fo I
-- -c'*i-'.
cLASs rEST 1 - MAcHTNE DESTcN
23.08.1 0 1

Solve the following: Max marks: 20

'd

* specify
whelher the following stotemenl is conecl or not with reosons in brief.
i. o veclor quontity since it hos mognitude ond
Slress is
direction only.
2' ln bolh the conditions i.e. Plone srre"
Plone slroin, tne stresiei'in third direction ore
3' ln cose of elemenl loqded in pure "ni
sr'eorll.,e mox. principol stress will be twice of mox.
zero.
4' Design stress is olwoys token os ultimote
strenglh, whether moleriol is duclile or brillle.
sheor slress.
5 Foilure in brittle moteriol under prr.
t"riion wiil occur r'
i" v prr"" re p.roilel lo
" l./rvr vururter the
6. Von - Mises stress.is some os yield stress. ru rrre opplleo
opplied lood.
7
' Slress concentrotion
foclor o'epenoion geomelry of lhe element only
B. Enduronce limil ond enduronce strengtn";r.
some.
ond nol on the type of moleriol.
9'
,|0. Enduronce modificotion size foctor ioli iln
.or. of elemenlrr Jr4e
size wiih
stiffer the moterior more itwiil oefreci diometer /.Jmm
wrrrr ururlrerer z.5mm ond Iress.
I 1. Toughness ond hordness qre simitor;oteriol
properties.
i 2' Von - Mises.criterion is more
.onr.ruoriu" ihen Tresco,s criterion.
Solve^lhe following:
13. Derive the formulolion of Ssy 0.5 Syp
= for Moximum Sheor Skess Theory
l4' Drow the Mohr's stress chcles tor oriiue)to2(+ve)>o3(-ver r"Jt"i
l5' specify strengih ond weoknesrrr
vl6' Draw the lood diogrom ond sheoroiniurinrm oroy os engineering "r(+ve)>o2(+ve|>o3(zero).
mqterior.
force diogrom tor tre t6ttowi;t"#ffiiloment
diogrom of o simpry supporred beom. (5)
 E.i
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CSVTU Code:MEo9511
B.Tech.( Fifth Semester) Bxamination, April - May 2o1o
Subject: Machine Design-I
Branch: Mechanical Engineering
Time: Four hours Max Marks: 80
Min. Pass Marks: 28
Note: All questions are compulsory. Assume suitable data wherever necessary with justification.
Use of PSG data book and data sheets is allowed, Drawings to the scale are to be prepared on
separate drawing sheet to be attached with answer sheet.

Qu. L. Solve any one part of the following: (16)

(a) Find the safety factors for each of the following stress*states (MPa) under plane stress
conditions for ductile material with yield strength of 250 MPa and ultimate strength in
tension and compression as 400 MPa using (i) Principal Stress theory and (ii) Maximum
ShearStresstheory.DrawtheMohr'scircleofstressforboththecases.
a" oa oy _ 160 MPa Txy _ 60 MPa c.\try'.
b" ox _ -220MPa ; oy _ -70MPa Txy - 180 MPa c.c.\ry.

(b) A stepped shaft, with the reduction ratio of 1:2 is to have a fitlet radius of l}Y" of the
smaller diameter. The material of the shaft has noteh sensitivity factor of 0.925, a shear
U
stress of 160MPa at yietd and a shear stress of 120MPa at endurance limit. Determine the
diameter of the shaft at the minimum cross section to sustain a twisting moment if it
fluchrates}etween 500 Nm to - 800 Nm. Assume infinite life for the element.

Qu. 2. Solve any one part of the following: (16)

(a) Design a cotter joint to support an axial load of 30 kN. The material for all the
components of the joint is steel with the allowable stresses in tension, compression and shear
as 50 N/m*t, 60 N/mm2 and 35 N/mm2. While designing the sections draw the sketches of
the sections. Draw the designed joint (assembled) to the scale.
(b) Design a knuckle joint which connects two mild steel rods to transmit an axial load of
150 kN. Assume the workins stresses for both the pin and rod material as 80 N/mm2 in
tension, 68 N/mm2 in shear and 160 N/mm2 in crushing. Assume that the rods to be
connected are not very long. While designing the sections draw the sketches of the sections.
Draw the designed joint (assembled) to the scale.

Qu.3. Solve any one part of the following: (16)

(a) The force required to open or close a submerged sliding water gate is estimated at 27 kN.
It is required to design a single threaded steel screw such that one rnan exerting a pull of
360N at the periphery of a hand wheel 1.0m in diameter, attached directly to the screw
can operate the gate. The greatest unsupported length of the screw is found to be 1.5m.
Coefficient of friction for screw and collar is 0.15. The crushing strength of the material
is 210 MN/m2, the maximum working tensile or compressive stress is 70 MN/m2.
AssumeE=210GN/m2.

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p'.!Yt' 7"
 (b) A bolted assembly is subjected to an external force, which varies from 0 to 10 klr[. The
combined stiffness of the parts, held together by the bolt is three times the stiffness of
the bolt. The.bolt is initially so tightened that at 50oA overload condition, the parts held
together by the bolt are just about to separate. The bolt is machined from plain carbon
steel 50C4 ( Sut = 660 N/mm2 and Syt = fatigue stress concentration
460 N/mm2). The
factor is 2.5 and the expected reliability is 95o/o. The factor of safety is 2. Determine
the size of the bolt with coarse threads.

Qu.4. Solve any one part of the following: (16)

(a) Calculate the size of the weld required for an ecceltrically loaded weld as shown in
Fig.4(a). The allowable stress in the weld is 75 N/mm2.
(b) Find the diameter of the rivet in arrangement o-f the joint as shown in Fig.4(b). Maximum
shear stress in the rivet is limited to 65 N/mm'. The maximum load carried by the joint is
108 kN. Assume that all the rivets are of the same size.

Qu.5. Solve any one part of the following: (16)

_(a) A line shaft supporting two pulleys A and B, Fig.5(a) is receiving the power by means of
a vertical belt on pulley A, and is transmitted to pulley B carrying a horizontal belt. The
, ratio of belt tensions is 3:1 and the maximum tension in either belt is limited to 2.7 kN.
-a/*/ The shaft is made of plain carbon steel 40C8 (Sut = 650 N/mm2 and Syt = 380 N/mm2).
'/./V The pulleys are keyed to the shaft. Determine the shaft diameter according to the ASME
^
94 code if kr = 1.5 and kt = 1.0. Check the diameter for the torsional rigidity if the
)
permissible angle of twist between two pulleys is 0.5o and the modulus of rigidity is
79300 N/mm2.
(b) A transmission shaft, supporting two pulleys A and B and mounted between tra'o bearings
C1 and C2 is shown in Fig.5(b). Power is transmitted from pulley A to B. The shaft is
made of plain carbon steel 45C8 (Sut = 600 N/mm2 and Syt = 380 N/mm'). Th. pulleys
are keyed to the shaft. Determine the shaft diameter according to the ASME code if
kn = 1.5 and kt = 1.0. Check the diameter for the torsional rigidity if the permissible
angle of twist between two pulleys is 0.5o and the modulus of rigidity is 79300 N/mm2.

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1500 N

500 N

?700 N 900 N
Att clirrensions on e in rrrn't
Fig, 5( a )

30

C?

4000 N 500 N
Att dirnensions one in nnr
Fig,5(b)
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CSVT'U Course Code:MEo9511

B. Tech.(Fifth Semester) Examination, Nov. - Dec. 2oo9
Subject: Machine Design-I
Branch: Mechanical Engineering
TiEme: F'our hours Max Marks I80
Min. Fass Marks : 28
I{ote: All questions are compulsory, Assume suitable data wherever necessary with
justificatian. tlse of PSG data book and ISI data sheets are allowed. Drawings to the
scale are to be prepared on separate sheet.
*ffiry=*.'===-'-'''
Qu.x. S olve arly on e paitof-th e-follo-wing t
(a) The cantilevered shaft, Fig.t, is loaded only by the r8.z kN force. Ascertain the
factor of safety at the hatched crosd-section if the shaft is
(i) Ductile with a yield strength of 35o MPa,
iii) grittt" *i rti.tirirl *a-"J-p*Jri* ultimate strengths of 3oo and 75o MPa.

Mrlt is required to design a chain drive to connect a 15 kW, rooo qpm petrol
%engine to a conveyor. The driving sprocket is mounted on engine shaft. The driven
)ll
v- q^- sprocket is mounted on conveyor shaft. The conveyor shaft should run between
2z1-z41r?m.
225-245 r?m. 'I'he involve moderate sno
cqnditions lnvolve
service cqndltrons
The Servrce shocks.
v^t9fuV fil Select a proper roller chain and give a list of its dimensions.
v (ii)llll Determine the pitch circle diameters of driving and driven sprockets.
P:'i^",yr*^'::'*::':1"-*:::*r
(iii) Determine the number of chain links.
r

(iv) Specifir the correct centre distance between the axes of sprockets.

Qu.2. Solve any <rne part of the following: (r6)

(a) Design and d.raw the assembled view with fina} dimensions of a cotter joint to
support an axial load of z8 kN. The material for all the components of the joint is
steel with the allowable stresses in tension, compression and shear as 50 N/mme,
6o N/mmzand 35 N/mmz.
(b) Design and draw a coupling of flange type for connecting the motor and
centrifugal pump shafts. The details of the duty required from the coupling are:
power to be transmitted 18 kW, speed in rev/min 1ooo" Find the diameter of the
motor and pump shaft. The allowable stress in shear and crushing is limited to
5o N/mm2 and roo N/mma and the angle of twist is not to exceed o.i5 degrees
in a length of zo diameters. The allowable shear stress in the coupling bolts is
Bo N/mm2. Assume the torsional mqment to be transmitted is zo% more than the
mean torsional moment. The material for the shaft, key and flange is same.

Qu.g" Solve any one part of the following: (16)

(a) In the design of a new size reciprocating air compressor, it is proposed that eight
bolts be used to fasten the head to the cylinder" The cylinder bore diameter is 75
mm, and the maximum working pressure will be g.S N/mms" Desigr the bolts
for a factor of safety of 3 under the following conditions:

PTO
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i\-/:i\' i
ar'-to)ii
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J
iiJi
1r{$ t
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(i) A compressible gasket seal will be used between the head and the cylinder. The
gasket is made from a fibre'sheet, and preliminary calculations indicate that an
initial compression load of about 6+ kN is required on the gasket for a leak proof
seai.
(ii) An o-ring seal is used with metal to metal contact between the head and the
cylinder, and a torque wrench is used to screw up the nut to give the desired initial
tension load.
The stresses given for the bolt material are ! oyp, = {/a.o N/mmz, oe = 22o.o
N/mm2, ou = 55o.o Ny'mma,. The material is machine finished. Stress
concentration factor maybe taken as 2.o.

ft),It is required to design a fly-press, €rs shown in figure, Fig.g, capable of punching
r\-4./
r./ i6omm diameter circles from a 2mm thick mild steel sheet. The ultimate shear
strength of sheet metal is 4oo N/mm2 and it can be assumed that shearing will be
_Y cornplete when the punch penetrates through half the thiekness of the sheet. The
J' -e screw, with square threads, is made of steel SoCS (Sy, = 4eo N/mm'), while the
/
.- nut is made ol bronze. The factor of safety is 3. The operator is expected to seat in
V i/ front of the fly-press, insert the sheet by his left hand and operate the handle by the
{, right hand. The total working stroke consists of one-quarter revolution, 45o in
.Y
^eu
front of the press and 45" behind the press. During the return stroke, the punch is
raised by 7 mm to provide clearance to insert the sheet. The forward or working
stroke is complete in z sec. The balls are made of cast iron, with a mass density of
7z8o kglms,andthe radius R' is 5So mm. Neglecting collar friction, determine:
(i) The dimensions of screw;
(ii) The length of nut;
{iii) The size of balls.
Qu.4. Solve anytw'o part of the following: (8,8)

(a) A 50-kN load is transferred from a welded fitting into a 200-mm steel channel as illustrated
in figure, Fig.4(a). Estimate the maximum stress in the weld.
(b) Determine the throat and leg dimensions for the welds of an eccentrically loaded bracket
welded to the support as shown in figure, x.ig. a(b). The permissible shear stress for the weld
material is 55 N/mm2 and the load is static.
G)' A boiler joint is to be designed for a steam pressure of z.5N/mm2. The inside
diameter of the largest course of the drum is r.35 m. The complete joint is shown in
figure, Fig.4(g). The allowable stresses are ot = 78.o N/mm2, t = 62.5N/mm2,
oc = 135.O N/mmz

Q.5. Solve any one part of the following:

(a) The arrangement for a transmission shaft is shown in figure, Fig.S, r8.75lau is to be
transmitted through the shaft at r5o rev/mm. The gear tooth reaction acts
vertically upward as shown. The flywheel 'F'delivers the power vertieally downward
through a belt, the tension on the tight side Fr, being 2.5 times the tension on the
slack side, Fz. The gear weighs 9oo N, the flywheel 27oo N and both are keyed to
the shaft. The shaft is made of o.4o per cent carbon steel that has an ultimate
tensile strength of 4go MPa and an elastic limit of z8o MPa. l,oads may be
considered suddenly applied, but with minor shocks only. The weight of the,shaft is

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assumed to be negligible in comparison to other loads. Determine the diameter of

the shaft.
(or)
(h\A uniform solid shaft ABCDE, Fig.s&), is supported in bearings at A and D, and
,igtates at 9oo rev/min (rpm). So kW are delivered to the shaft through the 56o
"mm diameter belt pulley at C. 3o kW are extracted via the z8o mm diameter
pulley at B, and zo kW at the z1o mm diameter pulley at E. At each pulley, the two
belt strands are,parallel and the ratio of tensions in them is g:r. Determine the
minimum acceptible shaft diameter if the design stress of roo MPa incorporates an
allowance for fatigue

PUNCH

Fig.r Fig.3.

o -.1
f"-*-* 200
f*- a

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w\ J

7y= O.il
,\r}\
\

Alt dimensions are in mm.

Fig.4(a)

frTo
 tj"y'

ffiS e{ s-$

Ail dimensions are in mrn

Fig.4(c)

*e
T rt
h
(ht
-a
{t

I i.,L*Jo.soL
*f
Alt dimensi<lns are in meters.
.I

rr
Fig.S(a)

lr.-l- Yrnt?'l-'
ls Att A'irncnstsrns drtcg
Fig.s&)

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ti

CSVTTJ Noverryrkxr- Code;MES8s11

B.Tech,Siffh Semester) Examinaation, Ilecemtrer 2S{}8
Subject: Machine Design-I
Branctr: Mechanisal Engineering
Time: Four hours Max lVlarksl 80
Min. Pass Marks: 28
Note; All questions are compulsory. Corresponding figures are attached in the last
page. Assume suitable data wherever necessary witlt justifipation; Use of PSG data
book ancl data sheets are allowed.

Qu. 1. Solve any two part of the followiug: (B,B)

(a) Find the most critically stiessed location on the stepped circular bar, F ig. L. Show the stress
values at these locations. l

(b) A transmission shaft carries a pulley rnidway between the two bearings. The bencling
moment at the pulley varies from 200 N-rn to 600 N-m, as fhe torsional rnoment in the
sirafl varies frorn 70 N-m to 200 N-m. Ttre frequencies of variation of bending and
torsional moments are equal to the shaft speed, The shaft is made of steel FeE 400 ( Sut =
540 N/mm2 and Syt = 400 N/mm2). The corrected endurance strength of the shaft is 200
N/rnp2. Determine the diameter of the shaft using a factor of safety Z.

kW, 1400 rpm electric motor

to a centrifugal pump running at 700 rpm. The sprvice conditions involve moderate
shocks.

Qu.2. Solve any one part of the following: (16,16)

(a) Design a cotter joint to support an axial load of 30 ld.{. The material for all the
components of tire joint is steel.with the allowable stresses in tension, compression and
shear as 50 N/mm2, 60 N/mm2 and 30 N/mnn2. Show the individual failure area and
dimensions of the design element through neat sketch
I

(b) Design a knuckle joint which connects two rnild steel rods'tl ,r*r-i, an axial load of
200 kN. Assume the working stresses for both the pin and rod material as 80 N/mm2 in
tension, 70 N/mm' in shear and 150 N/mm' in crushing. Absume that the rods to be
connected are not very long. Show the individual failure arpa and dimensions of the
design element through neat sketch i

Qu.3, Solve any one part of the follorving I

(a) (i) Explain the foice deformation diagram of a bolted joint add develop the expression
(Pu),r,u*:P;[(k6' +kr')/kr'], where the symbols have their usual ineanings. (6)
(ii)A steel plate subjected to a force of 5 klr{ and fixed tb a dhannel by means of three
identical bolts,is shown in Fig. 3(a). The loits are made of plain carbon steel 30C8 ( Syt
= 400 N/mm2) and the factor of safety is 3. Determine itreinominal diameter of the
bolts. ii (10)
il

(b) It is required to design a double start screw with,square threaps for the C clamp shown
in figure, Fig.3{b). The maximum force exerted by the clamp [[s skN, It is assumed that
the operator will exert a force of 250 N at the ball handle of t$e hand wheel. The screw
is made of plain calbon steel 45C8 ( Syt = 330 N/mm2), while the nut is made of grey
o cast iron tr'G200. The dimensions of the collar are shown seRarlately in figure, The factor

i
jl
 '. the '!i\*'
of safety is 2.5. Dqtermine the ciirncnsions of the screw anrJ the uut and calculate "-|g
.

radiusR,ofthebaittandte. (16)
!

Qu.4. $ol'se arry onb p[rt of the follorving: {l{i"16)

(a) A solid iircufa{ shaft, 25mm in cliameter, is welded to a'support by means of a fillet
weld as shown [n fig.nqa1. Determine the leg climension of the weld if the perinissible
shear stress is 95 N/mm'.
.{ I

(b) The riveted **Lnb.t shown in figure, Fig.aft) is fastened to a beam, arrrl an eccentric
loacl is appliedi fuvets A and C ll.ave 16 mrn diameter and at B and D have
22 rnw.
detetmine the f'actor
diameter; Assuming the yield strength of the rivet as 580 N/mm2,
of safety igainqt the shear of the rivets.
i

Qu.S, Solve any one pprt of the following:

(a) A uniform rotia rn* ABCDE, fig"S(a) is rypported in bearings at A and l), and
rotates at 900 nev/min (rpm). 50 kW at'e cielivered to the shaft through
the 560 mrn
diameter belt pglley at C. 30 kW are extracted via the 280 mm diameter pulley ai
fl,
and 20 trW at the 210 mm diameter pulley at E. At each pulley, the tlvo belt strands
are

parallel and th,b ratio of tensious in them is 3:1. Detennine the minimrtrn acceptabie
slaft diameter if the clesign stress of 100 MI'a incorporates an allowance for fhtigue.
ii

(b)' A ffansmissiori shaft supporting two pulleys A and B md mounted befween two
' bearings C1 and C2 is slioram in Fig.S(h). I'owcr is t'ansmitted {rom-pulls-; A to B. The
shaft is made cf piain carbon steei"4sc'S ( Suf = 600 N,'mmz aud Syt - 38tt Nlmm2).
The pulleys are ke,ved to the shaft. Detemrine the shaft diameter using the ASME
code
if ko=1.5 and.kt=l.$. Also determine the shaft diameier on the basis of torsional
rigidity, if the permissibie-angle of twist befween trvo pulleys is 0.50 and the niodiiius
of rigidity is 79300 N/mrn'.

/\
y'"''r-.
(?-h, \
 Atl. ciir"rensions cne in mn
' FrSJ(a)
AII dimensions are in mm

Fig.3(a)
(a)
Fiq.4
'ri
ii

FRAME

H andwheel
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Fig"4(b)
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Jt ;5il D
b.t*=-' :

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Fig.5(a)

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CSVTU .... Code:MEo75u

B.Tech.( F-ifth Sernester) Examination, December z.oaT
' Subject: Machine Design-I
Branch: Mechanical llngineering
Time: Four hour NIax Marks:80
NIin. Pass Marks: 28
Note: Atl questions are compulsory. Assume suitable data wherever necessary with
justification. Use of PSG data book and data sheets are allowed. Drawings to the scale are to
be prepared on separate drawing sheet to be attached with answer sheet.

Qu. 1. Solve any one part of the following:

(a) Find the safety factors for each of the following two-dimensional stress states
under plane stress conditions for ductile.material with yield strength of 500 MPa via
(i) distortion energy theory and via (ii) maximum shear stress theory
A. ox = B0 i '(fy = L7A , Txy = 60 C.w.
b. ctx = -220 , oy = -7A , T^y = l$$c.c.vl.
c. oy - -205 i sv _ - 445 i rxy - 35 c.w. ( 16)

(b) tt is required to design a chain drive with a duplex chain to connect a rF kW,
14oo rpm electric motor to a transmission shaft running at 3So rprn. The
operation involves moderate shock. As a preliminary design the eenter distance can
be assumed as 4o times the pitch of the chain. (t6)

Qu.z. Solve any one part of the following:

(a) Design a cotter joint to support an axial load of z8 kN. The material for all
the components of the joint is steel with the allowable stresses in tension,
compression and shear as bo N/mm2, 6o N/mmz and 35 N/mmz, Draw the
designed joint (assembled) to the scale. (r6)
(b) Design a knuckle joint which connects two mild steel rods to transmit an
axial load of r5o kN. Assume the working stresses for both the pin and rod
material as 8o N/rnm2 in tension, 68 N/mm, in shear and 16o N/mmz in
crushing. Assume that the rods to be connected are not very long. Draw the
assembled joint to the scale. f{6)

Qu.3. Solve any one part of the following

(a) A bolted assembly is subjected to an external force, which varies from o to 10
kN. The combined stiffness of the parts, held together by the bolt is three
times the stiffiress of the bolt. The bolt is initially so tightened" that at 5oo/o
overload. condition, the parts held together by the bolt are just abodt to
separate. The bolt is machined. from plain carbon steel 5oC4 ( S,rt = 66o
N/mm, and Syt = 46o N/mmr). Ihe fatigue stress concentration factor
is 2.5 and the expected reliability is gSY". The factor of safety is z.
Determine the size of the bolt with coarse threads. (16)

a
^J

{ c,;
tn ivr
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(b) Uesillfuhe screw drive of a jack for load capacity of roo N. The lifting height is
o.Sm. The basic design of the jaclc is as given in Fig.3. Assume the material for
the screw as Cz5'steel and for nut as phosper bronze. Determine the
different dimensions of the screw and check it against the induced stresses.
Assume coefficient of friction for nut and. screw as o,la5. (16)
t

!trf
\r

tTi =0.45*'.1" 1

b*e:i- - I

t,:
-L
'{'

Fig.3
Qu.4. Solve any one part of the following:
(a) A roo klrl load is transrnitted from a weld fittihg into a zoo mur steel channel
. as shown in FiS.+(a). Estimate the. maximum stress in the weld. All
dimensions are in mm. (16)
66

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I

i r ,r'"r
I

t,
I

ri
l-, -Y
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I
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Fig.4 (a)
 (b) A Hkcket is to be attached to a wall with the help of six rivets. The different
arrangements in which,the bracket can be attac-hed to the wall with these rivets
are shown in Fig.4ft). The maximum allowable stress in shear is 6o N/mmr.
Deternrine the way in which the rivets should be arranged so that the design is
econ<imical. fhe bracket is required Io support a load of 90 Id.I with an
eccentricity of zoomm. (16)
F)f
I \ ,---"^""-"---,

I
t

I
./'
//ti
i
*"'"^'i ltlu
I f'-J t'
//*2"'-..-
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/ ,i

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/
.,
f

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.t
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;' R l0t)
I

F) F=-- pl l-- 'l

I
I

.l
J'l
I

I
i
{ -(;)..
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i I

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I I

L
100
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t- i RL,LIL r\{t r\RRANGIf',lllN"l'

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Fig.a(b)
Qu.S. Solve any one part of the following:
(a) The layout of a two-stage zo kW V-belt speed reduction is shown below. The
first stage consists of a rz5 mm diameter engine-driven input pulley
rotating at 24oo rpm and drivint a 4oo mm diameter pulley mounted
on an intermediate shaft. The zoo mm diameter srnall pulley of the
second stage is also mounted on this intermediate shaft, and drives the 68o
mm diameter output pulley connected to the load. Tensions obtained from
belt:analyses are indicated on the sketch. The intermediate shaft abcd
has to be designed. Select suitable diameters Dr and Dz for the intermediate
shaft given that the duetile material's design stress, oa = Sln, is zg MPa.
(16)
 SEC HTiIF..STA#E : 5HEHlil

/ r E.Et

# 5[0. rnm

lf'lT EHI'/I ESIAT E f,HAFT

F IHST 5T,&fiE: 45 FZ I Hnn FH E Llhlihl$FT L#{TUtjT

(b) Determine the machine shaft diameter, running at 6oo rpm and supported
on bearings o.7bm apart. rS kW is supplied to the shaft through a o.45m
pulley located o.2bm to the right of the right bearing. The power is
i transmitted from the shaft through a o,2om spur gear located o.25lrr to
the right of the left bearing. The belt drive is at an angle of 6o" above the
horizontal. The pulley weighs 9oo N. The ratio of belt tensions is 3:r. The
gear has ts" pr"rrure angle and meshes with another gear located directly
above the shaft. The material properties are : Ultirnate strength = 49a i

MN/rirrnz, Yield point stress = 962 MN/mmz. Assume I(5 = t.5 and
IQ = 1.o. (16)

'4_

rt
/
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5
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B'E (rifth 2005

:ffi?i;;l?ffi1il*:fN'
TIME : Four hours M echqyn t c*P T*tB Ln*-eYiq Max. Msrks : 100

Min. Msrk$ ; 35

codes are allowed. Assume suitable

data wherever necessary. Drawings are to be made in a separate sheet to the scale.

Qu. 1. Solve any two part of the following:

:
----Lr'
(i) Compute the factor of safety for Max Normal Stress theory, Maximum Shear Stess theory
and Distortion Energy theory, for the foltowing state of stress. The material has a yield
strength of 600 MPa. Plot the resulb.
a. 01 * 42A MPa, o2 = 420 MPa, $s = 0
b. or = 0 MPa , 62 = -L80 MPa, os = -42A MPa {10}
(ii) Design a cantilever bracket by determining its diameter to support a fully reversed bending
load of 500 N amplitude for 10e cycles with no failure. The cantilever is made of cold drawn
steel C50 having machined surface. The notch sensitivity factor at the fillet can be taken as
0.85. The operating environment is room temperature and the reliability factor is assumed at
9A7o. If the schematic diagram of the element is as shown in Fig.1 {10}

i:'

-i{,'(ii:j
{
rl
ii I

a-iii - -1-- - -- _*-i -r-:l*

i

I
I

irl
/i t-. r
I
y

.r '1I r--='-*-.__."..'--*'---J5'il ir^r t'l--.-**--**_J

(iii) A plate of width 1.4 m and length 2.8 m is required to supPort a tensile force in the 2.8 m
direction of 5 MN. Inspection procedures detect through thickness edge cracks iarger than 3
mm. The two Aluminum alloys are being considered for this applicatiory for which the
safety factor must be 1.4 and minimum weight is important Which alloy should be used, if
fracture toughness is govemed by the equation, KI = 1.2 o{ fia'
Alloy Krc, MPa {m $r, MPa
A1 26 455

fe} 24 495 (10)

rotates at 800 rev/min

Qu. 2. (a) A uniform solid shaft ABCDE is supporbed in bearings at A and D, and
(rpm). 50 kW are delivered to the shaft through the 560 rnm diameter belt pulley at C. 30 kW are
exbacted via the 280 mm diameter puley at B, and 20 kW at the 210 mm diameter pulley at E. At each
pulley, the two belt strands are parallel and the ratio of tensions in them is 3:1. Determine the minimum

nr.c "
 ,t--------------1
i

I
---'
'- ' accePtable shaft diameter if the deeign stress of 100 MPa incorporates an allowance for fatigue, (?01
I

,*t 50

(b) The layout of a two'stage 30 kw V-belt r** ,(:t*tion

is shown below. The first stage consisb of a
125 mm diameter engine-driven input pulley rotating at2400rev/min and driving u ld** diameter
pulley mounted on an inbermediate shaft. The 200 nm diameter
small puiley of the second stage o
diameter outpuf puiley connected to"rr"
mounted on this intermediate shaft, and drives the 630 mm
the
load' Tensions obtained from belt analyses are indicated
on the skekh. The intermediate shaft abcd has
to be designed' select suitable diameters D1 and D2 for the
intermediate shaft given that the cluctile
maberial's clesigr shess ( cr.r = S/n ) is 25 Mpa.
(20)

Nol to sesl*
Slrnensi*ns in nnm

9
,s*'

INTERMEDIATE 5I.IAFT
PBELIhIF{AFY LAYflJT

Qu- 3- {a} which lap joint is *rorc *ffectivc, the transverse or the langitutlinntr, ftnd by how much

{2s}

.T:
L,.
f,
*

(b) A 6000 kg toad is to be supported by

a a" s ern thick br**$qet fastsned to a 3 em thick rnfrin plate with
S
rivets as shown in Fig. 3(b). catculate the size
of the riv*t if the allowable shear stress is 1000
kg/cma. All
dimensions are in mm.
{20}

P.To.