Code No: R5310305 1

III B.Tech I Semester(R05) Supplementary Examinations, May 2009

DESIGN OF MACHINE MEMBERS-I
(Mechanical Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
?????

1. A shaft as shown in figure 1 is subjected to a bending load of 3 kN, pure torque of 1000 N-m and an axial pulling
force of 15 k.N. Calculate the stresses at A and B.
[16]

Figure 1:

2. (a) Discuss the factors affecting endurance limit.

(b) A stepped shaft has maximum diameter 45 mm and minimum diameter 30 mm. The fillet radius is 6 mm. If
the shaft is subjected to an axial load of 10 kN, find the maximum stress induced taking stress concentration
in account.
[8+8]
3. (a) What are the assumptions made in the welded joints.
(b) A 125 ×95×10 mm angle is joined to a frame by two parallel fillet welds along the edges of 150mm leg. The
angle is subjected to a tensile load of 180 kN. Find the length of the weld if the permissible static load per
mm weld length is 430 N. [4+12]
4. (a) Define the following terms with necessary sketch.
i. Major diameter
ii. Minor diameter
iii. Pitch
iv. Lead.
(b) Derive an expression for the maxim load in a bolt. When a bracket with a circular base is bolted to a wall
by means of four bolts. [8+8]
5. (a) What are the various types of keys? Discuss their merits and demerits?
(b) Select a key for a 100mm dia shaft transmits 750kW at 1000r.p.m. The allowable shear stress in the key is
100MPa and the a allowable compressive stress is 200MPa. What type of key should be used if the allowable
shear stress is 30MPa and the compressive stress is 120 MPa. [8+8]
6. (a) Differentiate between torsional rigidity design and lateral rigidity design of shafts.
(b) A shaft transmitting 100kW power is running at 180 r.p.m satisfying the following conditions, determine
the size of the shaft.
i. Shear stress should not exceed 50MPa.
ii. Angle of twist should not be more than 10 on a length of 16 times the diameter. Take G=0.84×105 MPa.
[6+10]
7. A mild steel shaft has to transmit 70kW at 240rpm. The allowable shear stress in the shaft material is limited to
45MPa, and the angle 1o in a length of 20 times the shaft diameter. Determine the shaft diameter, and design a
cast iron flange coupling of protected type for the shaft. The shear stress in the coupling bolts is to be limited
to 30MPa. [16]
8. (a) What is the advantage of leaf spring over helical spring?
(b) Design a helical compression spring to carry a load of 1.5kN with a deflection of 40mm. Spring index 5.
Allowable shear stress is 400N/mm2 . Modulus of rigidity is 8×1010 N/m2 . [4+12]

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Code No: R5310305 2
III B.Tech I Semester(R05) Supplementary Examinations, May 2009
DESIGN OF MACHINE MEMBERS-I
(Mechanical Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
?????

1. (a) Define the terms load, stress and strain. Discuss the various types of stresses and strains.
(b) Explain the difference between linear and lateral strain. [10+6]
2. (a) Explain the following terms in connection with design of machine members subjected to variable
load.
i. Endurance limit
ii. Size factor
iii. Surface finish factor
iv. Notch sensitivity.
(b) A leaf spring is an automobile is subjected to cyclic stresses. The average stress = 150 Mpa.
Variable stress = 500 Mpa; ultimate stress = 630 Mpa; yield point stress = 350 Mpa and endurance
limit =150 Mpa. Estimate, under what factor of safty the spring is working, by Goodman and
Soderberg formulae. [8+8]
3. Design the longitudinal and circumferential joint for a boiler whose diameter is 2.4 meters and is
subjected to a pressure of 1N/mm2 . The longitudinal joint in a triple riveted butt joint with an
efficiency of about 85% and circumferential joint in a double riveted lap joint with an efficiency of
about 70%. The pitch in the outer rows of the rivets is to be double than in the inner rows and the
width of the cover plates is unequal. Allowable stresses are.
σt = 77MPa; τ = 56MPa; and σc = 120MPa. [16]
4. (a) Discuss the significance of the initial tightening load and the applied load so far as bolts are
concerned.
(b) The cylinder head of a steam engine is subjected to a steam pressure of 0.7N/mm2 . It is held
in position by means of 12 bolts. A soft copper gasket is used to make the joint leak proof. The
effective diameter of the cylinder is 300 m.m. Find the size of the bolt so that the stress in the
bolt is not to exceed 100 MPa. [6+10]
5. (a) How is the slipping of the cotter avoided? Explain by two methods.
(b) Design a knuckle joint to transmit 120 kN, with permissible stresses in tension; shear and com-
pression are 75 Mpa; 60 Mpa and 150 Mpa respectively. [4+12]
6. (a) Whata is the comparison between solid shafts, hollow shafts and spindles.
(b) Compute the diameter of a solid shaft which has to transmit 16kW power at 300rpm. Ultimate
shear stress per shaft material is 350N/mm2 and factor of safety for design is 6. If a hollow shaft
replaces the solid shaft, find the inside and outside diameters if the ratio is 0.5. [6+10]
7. Design a bushed -pin type flexible coupling to connect a pump shaft to a motor shaft, transmitting
32kW at 960rpm. The overall torque is 20% more than mean torque. The material properties are as
follows :
(a) The allowable shear and crushing stress for shaft and key material is 40 MPa
(b) The allowable shear stress for cast iron is 15MPa
(c) The allowable bearing pressure for rubber bush is 0.8N/mm2
(d) The material of the pin is same as that of shaft and key
Draw neat sketch of the coupling. [4×4=16]
8. (a) What is a spring and how they are classified?
(b) Design a spring for spring loaded safely valve for the following:
Conditions: Operating pressure 100N/cm2 . Diameter of valve seat 100mm. Design shear stress
for the spring is 400 N/mm2 ., G=0.86 ×105 N/mm2 . The spring is to be kept in a casting of 120
mm inner diameter and 400 mm long. The spring should be at maximum lift of 6mm when the
pressure is
107.5 N/cm2 . [4+12]

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Code No: R5310305 3
III B.Tech I Semester(R05) Supplementary Examinations, May 2009
DESIGN OF MACHINE MEMBERS-I
(Mechanical Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
?????

1. A copper bar 50 mm in diameter is placed with a steel tube 75 mm external diameter and 50 mm internal
diameter of exactly the same length. The two pieces are rigidly fixed together by two pins 18 mm in diameter,
one at each end passing through the bar and tube. Calculate the stress induced in the copper bar, steel tube
and pins if the
± temperature of the
± combination is raised by 50%. Take
Es = 210 GN m2 ; Ec = 105 GN m2 αs = 11.5 × 10−6 /o C and αc = 17 × 10−6 /o C.
[16]
2. (a) Discuss the factors affecting endurance limit.
(b) A stepped shaft has maximum diameter 45 mm and minimum diameter 30 mm. The fillet radius is 6 mm. If
the shaft is subjected to an axial load of 10 kN, find the maximum stress induced taking stress concentration
in account.
[8+8]
3. (a) Classify the rivet heads according to Indian Standard Specification.
(b) A double riveted lap joint is made between 15mm thick plates. The rivet diameter and pitch are 25mm and
75mm respectively. If the ultimate stresses are 400 MPa in tension and 320 MPa in shear and 640 MPa in
crushing, find the minimum force per inch, which will rupture the joint. If the above joint is subjected to
a load such that the factor of safety is 4, find out the actual stresses developed in the plates and the rivets.
[6+10]
4. (a) Discuss the significance of the initial tightening load and the applied load so far as bolts are concerned.
(b) The cylinder head of a steam engine is subjected to a steam pressure of 0.7N/mm2 . It is held in position
by means of 12 bolts. A soft copper gasket is used to make the joint leak proof. The effective diameter of
the cylinder is 300 m.m. Find the size of the bolt so that the stress in the bolt is not to exceed 100 MPa.
[6+10]
5. (a) For any sunk key, the crushing strength should be at least twice the shear strength, prove it?
(b) What is the basis of design for the following parts in a cotter joint?
i. Cotter
ii. Margin in inner part of the cottered joint
iii. Diameter at the end. [8+8]
6. (a) Explain the reasons for preferring hollow shafts over solid shafts.
(b) A shaft, 2m long between bearings, carries a 900N pulley at its mid-point. Through a belt drive, the shaft
receives 25kW at 180 r.p.m. The belt drive is horizontal, and the sum of the belt tensions is 7kN. Determine
the shaft diameter and angle of twist, the shaft undergoes. Take G= 80GN/m2 . [4+12]
7. A protective flange coupling is used to connect two shafts and transmit 7.5kW power at 720 r.p.m. The design
torque is 150% of the rated torque. The shafts and the bolts are made of plain carbon steels 30C8(σyt =400N/mm2 )and
the factor of safety is 5. Assume, (σyc =1.55σyt and σsy =0.5 σyt ) The flanges are made of cast iron, Calculate:
(a) diameter of shafts
(b) number opf bolts and
(c) diameter of the bolts. [16]
8. A locomotive spring has an overall length of 1.5m and sustains a load of 85kN at its center. The spring has 3
full length leaves and 15 gradual leaves with a central band of 120mm wide. All leaves have to be stressed to
430 N/mm2 when fully loaded. The ratio of spring depth to width is 3. Take E = 2.1 ×105 N/mm2
(a) Find width and thickness of leaves.
(b) Find the initial space that should be provided between the full-length leaves and graduated leaves before
the band load is applied.
(c) What load is exerted on the band after the spring is assembled? [16]

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Code No: R5310305 4
III B.Tech I Semester(R05) Supplementary Examinations, May 2009
DESIGN OF MACHINE MEMBERS-I
(Mechanical Engineering)
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
?????

1. A copper bar 50 mm in diameter is placed with a steel tube 75 mm external diameter and 50 mm
internal diameter of exactly the same length. The two pieces are rigidly fixed together by two pins 18
mm in diameter, one at each end passing through the bar and tube. Calculate the stress induced in
the copper bar,
± steel tube and pins
± if the temperature of the combination is raised by 50%. Take
Es = 210 GN m2 ; Ec = 105 GN m2 αs = 11.5 × 10−6 /o C and αc = 17 × 10−6 /o C.
[16]
2. (a) Write a note on the influence of various factors of the endurance limit of a ductile material.
(b) Determine the diameter of a circular rod made of ductile material with a fatigue strength (com-
pletely stress reversal) σe = 280 Mpa and a tensile yield strength of 350 Mpa. The member is
subjected to a varying axial load from 700 kN t - 300kN. Assume Kt =1.8 and F.S=2. [6+10]
3. (a) Show with neat sketches the various ways in which a riveted joint may fail.
(b) Two plates of 16mm thick are joined by a double riveted lap joint. The pitch of each row of rivets
is 90mm. The rivet are 25mm in diameter. The permissible stresses are as follows.
σt = 140 MPa; τ = 110 MPa; and σc = 240 MPa.. [8+8]
4. (a) Define the following terms with necessary sketch.
i. Major diameter
ii. Minor diameter
iii. Pitch
iv. Lead.
(b) Derive an expression for the maxim load in a bolt. When a bracket with a circular base is bolted
to a wall by means of four bolts. [8+8]
5. (a) Under what conditions the use of a knuckle joint is recommended? Name some of the engineering
applications of a knuckle joint.
(b) A knuckle joint required for a rod, which has to withstand a total load of 100kN. Find the
diameters of the rod and pin. Safe working stresses both in tension and shear are 65 N/mm2 .
Draw elevation and top view. [6+10]
6. (a) What is the effect of keyway on:
i. strength of shaft,
ii. Torsional rigidity of Shaft.
(b) Determine the inside and outside diameters of a hollow shaft, which will replace a solid shaft of
diameter 50mm. Both the shafts are made of the same material. The hollow shaft should be
equally strong in torsion, yet the weight should be half of the solid shaft. [6+10]
7. A protective flange coupling is used to connect two shafts and transmit 7.5kW power at 720 r.p.m.
The design torque is 150% of the rated torque. The shafts and the bolts are made of plain carbon
steels 30C8(σyt =400N/mm2 )and the factor of safety is 5. Assume, (σyc =1.55σyt and σsy =0.5 σyt ) The
flanges are made of cast iron, Calculate:
(a) diameter of shafts
(b) number opf bolts and
(c) diameter of the bolts. [16]
8. (a) Briefly explain the design of helical spring for fatigue loading.
(b) A helical coil spring is to be subjected, in service to loads ranging from 250 to 325 N. The axial
compression of the spring over the above load range is approximately 5mm. Assuming a spring
index of approximately 5, determine the
i. size of wire
ii. outside diameter of the spring , and
iii. the number of active coils. [6+10]

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