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ME2303 UNIT I PART B 1. (a) Give the general procedure in machine design.

1.Recognition of need: First of all, make a complete statement of the problem, indicating the need, aim or purpose for which the machine is to be designed. 2. Synthesis {Mechanisms)*, Select the possible mechanism or group of mechanisms which will give the desired motion. 3. Analysis of forces! Find the forces acting on each member of the machine and the energy transmitted by each member. 4. Material selections Select the material best suited for each member of the machine. 5. Design of elements (Size and stresses)1. Find the size of each member of the machine by considering the forces acting on the member and the permissible stresses for the material used. It should be kept in mind that each member should not deflect or deform than the permissible limit. 6.Modification: Modify the size of the member to agree with the past experience and judgement to facilitate manufacture. The modification may also be necessary by consideration of manufacturing to reduce overall cost 7.Detailed drawing. Draw the detailed drawing of each component and the assembly of the machine with complete specification for the manufacturing processes suggested. 8. Production. The component, as per the drawing, is manufactured in the workshop.

(b) What are the general consideration in machine design? (6)


1. Type of load and stresses caused by the load. 2. Motion of the parts or kinematics of the machine. The successful operation of any machine depends largely upon the simplest arrangement of the parts which will give the motion required. The motion of the parts may be : (a) Rectilinear motion which includes unidirectional and reciprocating motions. (b) Curvilinear motion which includes rotary, oscillatory and simple harmonic. (c) Constant velocity. (d) Constant or variable acceleration. 3. Selection of materials. 4. Form and size of the parts. 5. Frictional resistance and lubrication. 6. Convenient and economical features. 7. Use of standard parts. 8. Safety of operation. 9. Workshop facilities. 10. Number of machines to be manufactured. 11. Cost of construction. 12. Assembling.

(c) Give some important mechanical properties of the metals.(5) 1)STRENGTH 2)STIFFNESS 3)ELASTICITY 4)PLASICITY 5)DUCTILITY 6)BRITTLENESS 7)TOUGHNESS 8)MACHINABILTY 9)RESILENCE 10)FATIGUE 11) HARDNESS ------------------------*************** ---------------------------------(2) Solution. Given: W = 3 kN = 3000 N; T = 1000 N-m = 1 x 106 N-mm; P = 15 kN; d = 50 mm; x = 250 mm

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3) The frame of a punch press is shown in Fig. Find the stresses at the inner and outer surface at section X-X of the frame, if W= 5000 N. (16)

4) A C-clamp is subjected to a maximum load of W, as shown in Fig. If the maximum tensile stress in the clamp is limited to 140 MPa, find the value of load W.

5 a) An overhang crank with pin and shaft is shown in Fig. A tangential load of 15 kN acts on the crank pin. Determine the maximum principal stress and the maximum shear stress at the centre of the crankshaft bearing. (8)

t(max) =17.9 +27.5 =45.4 MPa. Maximum shear stress : max =27.5 MPa. --------------------------------------------*************** ---------- -------5)(b) A hollow circular column of external diameter 250 mm and internal diameter 200 mm, carries a projecting bracket on which a load of 20 kN rests, as shown in Fig. The centre of the load from the centre of the column is 500 mm. Find the stresses at the sides of the column. (8)

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6) A mild steel bracket as shown in Fig. is subjected to a pull of 6000N acting at 45 to its horizontal axis. The bracket has a rectangular section whose depth is twice the thickness. Find the cross-sectional dimensions of the bracket, if the permissible stress in t material of the bracket is limited to 60 MPa.

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7) A horizontal pull P = 5 kN is exerted by the belting on one of the cast iron wall brackets which carry a factory shafting. At a point 75 mm from the wall, the bracket has a T-section as shown in Fig. Calculate the maximum stresses in the flange and web of the bracket due to the pull.

8) A steel cantilever is 200 mm long. It is subjected to an axial load which varies from 150 N (compression) to 450 N (tension) and also a transverse load at its free end which varies from 80 N up to 120 N down. The cantilever is of circular cross-section. It is of diameter 2d for the first 50mm and of diameterd for the remaining length. Determine its diameter taking a factor of safety of 2. Assume the following values: Yield stress = 330Mpa Endurance limit in reversed loading = 300Mpa Correction factors =0.7 in reversed axial Loading = 1.0 in reversed Bending Stress concentration factor = 1.44 for bending = 1.64 for axial loading Size effect factor = 0.85 Surface effect factor = 0.90 Notch sensitivity index = 0.90 (16) Mean load Wm =150 N and Variable load W v =300N Mean axial stress m =191/d2 N/mm2 Variable axial stress v =382/ d2 N/mm2 Kfa=1.576 Endurance limit ea= 210 N/mm2 Equivalent normal stress nea =1428/d2 N/mm2 Consider reverse bending Mean load Wm =20N

Variable load W v =100N Mean bending stress m =Mm/Z =30550/ d3 N/mm2 Variable bending stress v = Mv/Z =152750/ d3 N/mm2 Kfb =1.396 Endurance limit eb=300 N/mm2 Equivalent normal stress at point A neb =337168 / d3 N/mm2 Total equivalent stress at point A ne= y /F.S =165 N/mm2 Diameter d=12.9 mm. -----------------------------------------*************** ----------------------------

9)A pulley is keyed to a shaft midway between two bearings. The shaft is made of cold drawn steel for which the ultimate strength is 550 MPa and the yield strength is 400 MPa. The bending moment at the pulley varies from 150 N-m to + 400 N-m as the torque on the shaft varies from 50 N-m to +150 Nm. Obtain the diameter of the shaft for an indefinite life. The stress concentration factors for the keyway at the pulley in bending and in torsion are 1.6 and 1.3 respectively. Take the following values: Factor of safety = 1.5 Load correction factors = 1.0 in bending, and 0.6 in torsion Size effect factor = 0.85 Surface effect factor = 0.88 (16) Mean load Mm =125 N-mm and Variable load M v =275 N-mm Mean axial stress m =1273000/d3 N/mm2 Variable axial stress v =2800000/ d3 N/mm2 Endurance limit eb= 275 N/mm2 Equivalent normal stress neb =1428/d3 N/mm2 Torsional moment: Tm= 50 N-m Variable Torque Tv =100 N-m Mean shear stress m =255000/ d3 N/mm2 Variable shear stress v=510000/ d3 N/mm2 Equivalent shear stress es =1329000/ d3 N/mm2 Diameter =33.84mm say 35 mm. 10)(a) ) Determine the diameter of a circular rod made of ductile material with a fatigue strength (complete stress reversal), e = 265 MPa and a tensile yield strength of 350 MPa. The member is subjected to a varying axial load from Wmin = - 300 x 103 N to Wmax = 700 x 103 N and has a stress concentration factor = 1.8. Use factor of safety as 2.0. (8)

------------------------------------------------************* ---------------------------10)(b) A circular bar of 500 mm length is supported freely at its two ends. It is acted upon by a central concentrated cyclic load having a minimum value of 20 kN and a maximum value of 50 kN. Determine the diameter of bar by taking a factor of safety 1.5, size effect of 0.85, surface finish factor of 0.9. The material properties of bar at given by: ultimate strength of 650 MPa, yield strength of 500 MPa and endurance strength of 350 MPa. (8)

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