IIT JAMMU

DEPARTMENT OF MECHANICAL ENGINEERING

2019-20
Sample Questions: MEL211
Q.1) A 40 mm diameter shaft is made of forged steel 50C4 (Sut=660 N/mm2) has a machined surface. The expected
reliability is 99%. The theoretical stress concentration factor is 1.6. The notch sensitivity factor is 0.9. Determine
the endurance limit of the shaft.

Q.2) An intermediate shaft of a gearbox, supporting two spur gears A and B and mounted between two bearings
C1 and C2 is shown in Fig.1. The pitch circle diameters of gears A and B are 600 and 300 mm respectively.
The shaft is made of alloy steel 20MnCr5 (𝑆𝑢𝑡 = 620 𝑁/𝑚𝑚2 & 𝑆𝑦𝑡 = 480 𝑁/𝑚𝑚2 ). The factor kb and Kt of the
ASME code are 2 and 1.5 respectively. The gears are keyed to the shaft. Determine the diameter of the shaft.
If the expected life for 90 % of the bearings is 8000hrs. Select the suitable single row deep grove bearings C 1
and C2 when the shaft rotate at 1450 rpm.

Fig.1 Fig.2
Q.3) It is required to design a spur gear speed reducer for a compressor running at 250 rpm driven by 7.5 kW, 1000
rpm electric motor. The center distance between the axis of the gear shafts should be exactly 250 mm. The
starting torque of the motor can be assumed to be 150% of the rated torque. The gears are made of carbon
steel, 50C4 (𝑆𝑢𝑡 = 600 N/mm2). The pressure angle is 20 degree. The factor of safety is 2 for preliminary design
based on the use of velocity factor. Design the gear and specify the dimensions. Assuming manufacturability
of grade Class II, calculate the dynamic load by using Buckingham’s equation. Determine actual factor of
safety against bending failure. Using same factor of safety to determine the surface hardness to constrain the
failure due to pitting wear.
Q.4) A bracket is attached to a column by means of 4 bolts as shown in Fig. 2. The load of 20 kN is acting at an
angle of 45 degree to vertical plane. Determine the size of the bolt. Assume the allowable shear strength of
bolt material as 130 MPa. If two bolts 2 and 4 are placed at a distance of 15 mmm instead of 30 mm from O,
is there being any improvement in design?

Q.5) Design and draw a cotter joint to support a load of 5 kN. The allowable stresses in tension, shear and crushing
are 56 MPa, 45 MPa and 98 MPa.

Q.6) In an axial flow rotary compressor, the shaft is subjected to a maximum torque of 1500 N-m and a maximum
bending moment of 3000 N-m. Neglecting the axial load on the compressor shaft, determine the diameter of
the shaft. Assume that the load is applied gradually. The shear stress in the shaft is limited to 50 N/mm 2. Also
design a hollow shaft for the above compressor taking inner diameter as 0.4 times the outer diameter. What
is the % saving in hollow shaft? Compare the stiffness. What will be the shear stress if an axial load of 1000
kg is taken into account?

Q.7) Write down selection procedure of rolling element bearing. In a particular application, the radial load acting
on a ball bearing is 5 kN and the expected life for 90 % of the bearing is 8000hrs. Calculate the dynamic load
carrying capacity of the bearing when the shaft rotate at 1450 rpm.
Q.8) Write down selection procedure of rolling element bearing. In a particular application, the radial load acting
on a ball bearing is 5 kN and the expected life for 90 % of the bearing is 6000hrs. Calculate the dynamic load
carrying capacity of the bearing when the shaft rotates at 3000 rpm.
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DEPARTMENT OF MECHANICAL ENGINEERING

Q.9) Design a pair of spur gears with 200 full- depth involute teeth consisting of a 20 teeth pinion meshing with a
50 teeth gear. The pinion is connected to a 20 kW, 1440 rpm electric motor. The starting torque of the motor
can be taken as 150% of the rated torque. The material for the pinion is Fe 410 while the gear is made of FG
200. The factor of safety is 1.5. Design the gears based on the Lewis equation.

Q.10) It is required to design a helical compression spring subjected to maximum force of 1250 N. The deflection of
the spring corresponding to the maximum force should be 30 mm. The spring index can be taken as 6. The
spring is made of cold drawn steel wire (G= 81370𝑁/𝑚𝑚2 ,, 𝑆𝑢𝑡 = 1090 𝑁/𝑚𝑚2 ). The permissible shear stress
for the spring wire should be taken as 50% of the ultimate tensile strength. Design the spring and calculate;
a) Wire diameter
b) Mean coil diameter
c) No. of active coils.
d) Total no. of coils.
e) Free length of spring
f) Pitch of the coil
Q.11) It is required to design a spur gear speed reducer for a compressor running at 250 rpm driven by 7.5 kW, 1000
rpm electric motor. The center distance between the axis of the gear shafts should be exactly 250 mm. The
starting torque of the motor can be assumed to be 150% of the rated torque. The gears are made of carbon
steel, 50C4 (𝑆𝑢𝑡 = 700 N/mm2). The pressure angle is 20o. The factor of safety is 2 for preliminary design based
on the use of velocity factor. Design the gear and specify the dimensions. Assuming manufacturability of grade
Class II, calculate the dynamic load by using Buckingham’s equation. Determine actual factor of safety against
bending failure. Using same factor of safety to determine the surface hardness to constrain the failure due to
pitting wear.
Q.12) A steel plate subjected to a force of 3 kN and fixed to a vertical channel by means of four identical bolts (Fig
3). The bolts are made of plain carbon steel 45C8 (𝑆𝑢𝑡 = 380 N/mm2) and the factor of safety is 2. Determine
the diameter of the shank. (05)

Fig.3
Q.13) A plate made of Steel (𝑆𝑢𝑡 = 400 N/mm2) in hot rolled and normalized condition is shown in Fig. 4. It is
subjected a completely reversed axial load of 30 kN. The notch sensitivity factor q can be taken as 0.85 and
the expected reliability is 90%. The size factor is 0.85. The factor of safety is 3. Determine the plate thickness
for infinite life.

Fig. 4

Q.14) Design a knuckle joint to connect two circular shaft subjected to an axial tensile force of 100 kN. The rods are
co-axial and a smaller amount of angular movement between their axes is permissible. Select the material of
joint as plain carbon steel 𝑆𝑢𝑡 = 400 N/mm2.
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DEPARTMENT OF MECHANICAL ENGINEERING

Q.15) A steel plate subjected to a force of 5 kN and fixed to a channel by means of three bolted identical bolts is
shown in Fig.5. The bolts are made of plain carbon steel 30C8 (Syt= 400 N/mm2) and the factor of safety is 3.
Determine the diameter of the shank. (10)

Fig.5
Q.16) A wall bracket with a rectangular cross- section is shown in Fig. 6. The depth of the cross section is twice of
the width. The force acting on the bracket at 600 to the vertical is 10 k N. The material of the bracket is grey
cast iron FG200 and the factor of safety is 3.5. Determine the cross section dimension of the bracket using
the maximum –normal stress theory of failure.

Fig. 6
Q.17) An intermediate shaft of a gearbox, supporting two spur gears A and B and mounted between two bearings
C1 and C2 is shown in Fig.7. The pitch circle diameters of gears A and B are 500 and 250 mm respectively.
The shaft is made of alloy steel 20MnCr5 (𝑆𝑢𝑡 = 620 𝑁/𝑚𝑚2 & 𝑆𝑦𝑡 = 480 𝑁/𝑚𝑚2 ). The factor kb and Kt of the
ASME code are 2 and 1.5 respectively. The gears are keyed to the shaft. Determine the diameter of the shaft.

Fig. 7
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DEPARTMENT OF MECHANICAL ENGINEERING

Q.18) A 50 mm diameter shaft transmitting 15 kW power at 200 rpm is supported on two ball bearings 750 mm apart
and two gears are keyed to it. The pinion and gear have 40 and 80 teeth respectively. The pinion is located at
100 mm to the left of the right bearing, whereas the gear is located at 150 mm to the right of the left bearing.
The module and pressure angle of the gear is 5 mm and 20 0 involute. Pinion deliver power horizontally to the
right and gear receives power in a vertical direction from below. Considering a load factor of 1.25 and expected
life of 12,000 hrs. Recommend suitable bearings
Q.19) A spur gear with pitch circle diameter of pinion and gear 150 and 450 mm respectively transmits 5 kW at 900
rpm of pinion. The pinion is made of 40C8 steel (𝑆𝑢𝑡 = 600 N/mm2) and gear is made of cast iron (𝑆𝑢𝑡 = 180
N/mm2). Taking pressure angle of 200 involute types, design the gear from strength and dynamic consideration.
Assume suitable parameters.
Q.20) The dimensions of an overhang crank are shown in Fig.8 The force P acting on the crank pin is 1 kN. The
crank is made of steel 30C8 (𝑆𝑦𝑡 = 400 𝑁/𝑚𝑚2 ) and the factor of safety is 2. Using maximum shear stress
theory of failure, determine the diameter d at section xx.

Fig.8
Q.21) A rotating bar made of steel 45C8 (𝑆𝑢𝑡 = 630 𝑁/𝑚𝑚2 ) is subjected to a completely reversed bending stress.
The corrected endurance limit of the bar is 315 𝑁/𝑚𝑚2 . Calculate the fatigue strength of the bar for a life of
90,000 cycles.
Q.22) For Supporting travelling crane in a workshop the brackets are fixed on steel column as shown in Fig. 9. The
maximum load that comes on the bracket 1200 kg, acting vertically at a distance of 40 cm from the face of the
column. The vertical face of the bracket is secured to a column by four bolts in two row (two in each row) at a
distance of 5 cm from the lower edge of bracket. Determine the size of the bolts if the permissible value of the
tensile stress for the bolt material is 840 kg/cm2.

Fig. 9